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3 <-/ "^ / n n r / - 

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TM 5-3431-226-15 



DEPARTMENT OF THE ARMY TECHNICAL MANUAL 

OPERATOR'S, ORGANIZATIONAL 
DIRECT SUPPORT, GENERAL SUPPORT 

AND 
DEPOT MAINTENANCE MANUAL 

WELDING SET 

ARC, INERT GAS SHIELDED: WATER COOLED 

ALUMINUM WELDING, GENERAL PURPOSE 

(AIRCO MODEL 2351 1209) 

FSN 3431-731-4163 



This copy is a reprint which includes current 
pages from Changes 1 



HEADQUARTERS, DEPARTMENT OF THE ARMY 



SAFETY PRECAUTIONS 

Trechloroethylene or methylchloroform will have toxic effects 
unless proper ventilation is provided, or if allowed to have 
prolonged contact with the skin. 

Point the cylinder valve away from your body before opening. 

Whenever steps are taken to remove and repair electrical 
hazards, place all power controls off and disconnect all electrical 
cabling from power sources. 



HKAD^UAKTEKS, 
DEPARTMENT OF THE ARMY 
WASHINGTON, D.C.. 28 September 1973 



Operator's, Organizational, Direct Support, 
General Support and Depot Maintenance Manual 

.DING SET, ARC; INERT GAS SHIELDED; WATER COOLED; ALUMINUM WELDING; 
GENERAL PURPOSE (AiRCO MODEL 2351 1209) FSN 3431-731-4163 



5-3431-226-15, 25 June 1969, is changed as 

vs: 

ii. Table of Contents. Appendix B is changed to 
"BASIC ISSUE ITEMS AND ITEMS 

DP INSTALLED OR AUTHORIZED". 
/. Paragraph 1.16. The second sentence is 

;ed to read "Appendix B contains the Basic 
Items and Troop Installed or Authorized 

i Lists." 

agraph 1.2.1 is added. 

. Reporting of Errors 

:an improve this manual by calling attention to 
; and by recommending improvements using 
Form 2028 (Recommended Changes to 
cations) or by a letter, and mail direct to Corn- 
ier, U.S. Army Troop Support Command, 
M: AMSTS-MPP, St. Louis, MO 63120. A reply 
je furnished direct to you. 
wing page 74. Page B-2 is rescinded in it en- 

76. Add the following before Section I, "Part 6, 

VY DUTY WATER CIRCULATOR, 10- 

.ON". 

Al. Paragraph 2 add the following. 



40-1 



46-5 



Color, Marking, and 
Preparation of Equipment 
for Shipment. 

Color and Marking of Army 
Materiel. 



agraph '.}, add the following. 



FM 29-2 Organizational Maintenance 

Management. 
TM 5-764 Electric Motor and Generator 

Repair. 

Paragraph 4. TB 740-93-2, is changed to read, 
"TB 740-97-2". 
Add the following: 

TM 38-230-2 Preservation, Packaging and 

Packing of Military Supplies 
and Equipment (Packing). 

Paragraph 5 is added. 

5. Demolition- 

TM 750-244-3 Procedures for Destruction of 

Equipment to Prevent 
Enemy Use. 

Paragraph 6 is added. 

6. Lubrication 

C9100IL Fuels, Lubricants, Oils, and 

Waxes. 

Paragraph 7 is added: 

7. Cleaning 

TM 38-230-1 Preservation, Packiaging, and 

Packing of Military Supplies 
and Equipment (Cleaning). 

Paragraph 8 is added. 

8. Operation 

TM 9-237 Welding Theory and 

Operation. 

Page B-l. Appendix B is superseded as follows: 



Section 9. INTRO DUCT1QN 



Scope 

ippendix lists items required by the operator 
ieration of the welding set. 

Generai 

list is divided into the following sections: 
lasic Issue Items List Section II. Not ap- 
>le. 

Items Troop Installed or Authorized List 
>n III. A list of items in alphabetical sequence, 
i at the discretion of the unit, commander may 
ipariy the welding aet. These items are NOT 
fECT TO TURN-IN with the welding set when 
ated. 

Explanation of Columns 

allowing provided an explanation of columns in 
ibular list of Basic Issue Items List, Section II, 
Items Troop Installed or Authorized, Section 



a. Source, Maintenance and Recouerability Code 
(SMR). Not applicable. 

b. Federal Stock Number. This column indicates 
the Federal stock number assigned to the item and 
will be used for requisitioning purposes. 

c. Description. This column indicates the Federal 
item name and any additional description of the 
item required. 

d. Unit of Measure (U/M). A two character 
alphabetic abbreviation indicating the amount or 
quantity of the item upon which the allowances are 
based, e.g., ft, ea, pr, etc. 



e. Quantity Furnished with Equipment 
Not applicable. 



(BULK 



f. Quantity Authorized (Items Troop Installed or 
Authorized). This column indicates the quantity of 
the item authorized to be used with the equipment. 



Section Hi. ITEMS TROOP INSTALLED OR AUTHORIZED LIST 



(2) 


(3) 


(4) 


(5) 


Federal stock 


Description 


Unit 


Qty 


number 


Ref No. ft niSr Utdble 


of 


auth 




coett . on code 


meat 




7520-559-9618 


CASE, Maintenance and Operation Manuals 


EA 


1 



rder of the Secretary of the Army: 



a*' 



CREIGHTON W. ABRAMS 
General, United States Army 
Chief of Staff 



:RNE L. BOWERS 

ijor General, United States Army 
e Adjutant Oerieral 



ibution: 

?o be distributed in accordance with DA Form 12-25A, (qty rqr block No. 182) Organizational main- 
ice requirements or Welding Sets. 



TM 5-3^31-226-15 



TECHNICAL MANUAL 
NO. 5-3^31-226-15 



HEADQUARTERS 

DEPARTMENT OF THE ARMY 

WASHINGTON, O.C., 25 June 1969 



Operator's, Organizational, Direct Support, 
General Support, and Depot Maintenance Manual 

WELDING SET, ARC, INERT GAS SHIELDED: WATER COOLED; 

ALUMINUM WELDING, GENERAL PURPOSE 

(AIRCO MODEL 2351 1209) 

FSN 3^31-731-^163 



PART 1 . GENERAL 

Section I. Introduction 
I I . Descri pt i on 

PART 2. 8000 SERIES FIXED 

PRESSURE REGULATORS 
Section I. Introduction 
II. I nstal lat i on 
III. Operation 
I V. Mai ntenance 

PART 3. AIRCOMATIC GUN 

MODEL AH35-C1 

Section I. Introduction 
II. I nstal lat i on 
Operation 
Mai ntenance 



PART 
Section 



/;. AIRCOKATIC PUSH-PULL WIRE 

FEEDER, MODEL AHF-E1 
I . I nt roouct i on 
II. I nstal lat ion 
Ml. Ope rat i on 
IV. Maintenance 



PART 5. AIRCOMATIC CONTROL 

MODEL AHC-B 

Section I. Introduction 
II. I nsta 1 lac i on 
III. Operati on 
IV. Maintenance 



Page 



12 

1': 
1C 
17 



22 

2;. 
2o 
30 



51 



57 

5u 

I?. 
C& 



r;,RT 



Section 



APPENDIX 



6. HEAVY DUTY WATER 

CIRCULATOR 

I . I ntroduct i on 

II. InstaT la 1 5 on 

III. Operation 

IV. Maintenance 

A. REFERENCES 

B. BASIC ISSUE ITEMS LIST 

C. MAINTENANCE ALLOCATION CHART 



76 
77 
77 



A-l 
B-l 
C-l 



PART I 
GENERAL 



Section I. INTRODUCTION 



1 . 1 Scope 



a. This manual is published for the use of personnel to whom 
the Arc Welding Set (Airco Model 2351-1209) is issued. The set 
consists of five end Itsms described in Parts II through VI. 
Each part furnishes instruction on the installation, Operation, 
and maintenance of a specific end item. 

b. Appendix A contains a list of publications applicable to 
this manual. Appendix B contains a list of basic issue items 
authorized the operator of this equipment. Appendix C contains 
the maintenance allocation chart. 

1.2 Forms and Records 

Forms and procedures vs ed for equipment maintenance -#111 
be only those prescribed in TM 38-750 (Army Equipment Record 
Procedures). 

Section II. DESCRIPTION AND MTA 

1.3 Description 

The five end items comprising the set are listed belov to- 
gether with their part numbers. 



Item 

Style 8000 Regulator 
Model AHC-1 Gun 
Model AHF-E1 Feeder 
Model AHC-B Control 
Water Circulator Unit 

l.k- Tabulated Data 
a. Welding Set/ 
Item 

Hose Connection Gland 
Hose Connection Nut (L.H.) 

Hose Connection Nut (R.H.) 



Part Number 



806 

2351 1150 

2351 1100 

2351 050^ 
2301+ 0171 



Part Number 

803-02JI7 

803-025^ 
803-0255 



Amount 

k 
2 
2 



Regulator 806-8054 1 

Argon Flow Adapter 830-1976 1 

50 Ft. Long Gas Hose 908-2210 1 

60 Ft. Long Water Hose 908-3210 1 

120 Ft. Long Welding Cable 1322-2000 1 

Terminal Lug 1323-0200 5 

Ground Clamp 0702-0002 1 

Water Circulator Unit .2304-0171 1 

10 Lb. Spool 3/614- in. 

Diameter 2332-5623 2 

Magnesium Aluminum Wire 
10 Lb. Spool 1/16 in. 

Diameter 2332-5624 2 

Magnesium Aluminum Wire 

Model AHC-B Aircomatic Control 2351-0504 1 

Model AHF-E1 Wire Feeder 2351-1100 1 

Model AH35C-1 Gun 2351-1150 1 

Secondary Contactor 2354-0102 1 

Wire Guide Component Kit 2354-0126 1 

Wire Guide Component Kit 2354-0127 1 

Hose and Cable Kit 2360-2204 1 

244 Cu. Ft. Cylinder W.P. 4 

Technical Argon 

FSN 8120-282-8077 

MIL-A-18455B 
Scratch Wire Brush, Steel, 2 

1 1/8 to 1 1/4 in. Lg., 

Clear of Block, l6 Rows Lg., 

4 Rows Wide, Shoe Handle, 

Straight Rectangular Face; 

4 3/4 to 5 in. Lg., Brush 

Parts; 10 1/2 in. Lg.; 

Federal Specification 

H-B~l78b, Type III, 

Class 1 

b. Auxiliary and Accessory Items. The remaining parts of the 
set consist of auxiliary items required for metal- inert-arc, 
gas-shielded welding of aluminum, in addition to accessory items 
required to adapt the major end items for use. 

. Wiring Data 

TT) Refer to figure 1 for the Electrical schematic diagram. 

(2) Refer to figure 2 for the wiring diagram control panel. 

(3) Refer to figure 3 for the interconnection schematic. 

(4) Refer to figure 4 for the gun and feeder wiring diagram. 



1-226-15 



ICAL MANUAL 



TSIO 



(RECTIFIER) 



, 211 



YI0244 

*0 VCT. 



IAL 
'PORT 



AL 



[ER COOLED 
;E 



ARMY 






T5 I0 
tit 


""1 If"" 


tit] VIO& B * ' VI05A 

;ffiM' AT7) 


ZJofiTil 1 2 27 

Tt 'oiijl L_ .0 .:..' 


DC WINDING ( 1 TS|05 

Of X 101 ~T x 1 x 


PL 103 s 
> 




CIRCUIT NUMBERING SYSTEM 


I0( 


. CIRCUIT! IN PROGRAM SECTION 
OF C.ON.TRQ.I PA MFI 


TSI07 
^ 


20 


. CIRCUITS IN ELECTRONIC SECTION 
OF CONTROL PANEL 


,10 


CIRCUITS IN CARRIAGE 


'SO 101 

rsior TSIOT 

^n p"" 

TS 107 ,.TJI07 

jo ioi > iw[lo7" 

73' 

C 
Tl lOi 


40 


) CIRCUITS IN GUN 










SVMUOL 


Dtri' ITKV 




It. 


BRAKi: 90LENOOJ 




C 


CAPACIIUK 




CH 


CONTROL RCUV 




r 


rust 




c 


WELD CURRENT SOURCl 




OS 


CAS SOLENOID 




IL 


ISDICATOH LWHT 




J 


JUMfEH 




L 


JMOOTIirNC CHOKE 




PL 


PLUG CONNECTOR 



we 



GUN 



,T5I07 SOIO| U1 T5 103 ' 



SOI02 



1W I04 



IWIOf 



il^ 

I 



Tt 107 

(P SSURE"SW ITCH; 

3S! P *" ?V' P l | 
,,02 T1W07 NN T 



MODCl AH 31X1-1 GUN (W 
(WATCft COOLCO; 




CAtlNG LINCR 

FUXIII.C SHAFT 



.WCLDINO CABLE 1 



Figur 



MOOCL AMJWM 'UN (MIL TVPC) 
(WATI* COOUO) 



WHTCft MLtNOlO 

WATCH PdtSSURt SWITCH 





WELO 



WIRE JOG 



PART 2 



8000 SERIES 

FIXED-PRESSURE 

REGULATORS 




Figure 1. Fixed- Pressure Regulator with Flow Adaptor 



Section I. INTRODUCTION 

1.1 DESCRIPTION 

The AIRCQRjSOOO Series Fixed-Pressure Regulators (Fig. 1) 
are for cylinder service. They are Single-Stage Metering 
devices designed for gas-shielded arc-welding applications. 
These regulators will supply a constant reliable flow of gas to 
meet specific job requirements. 

The regulator delivery pressure is preset to 30 psi and sealed 
during manufacture. Once the outlet of the regulator is fitted 
with aproper flow adapter, a constant flow of gas will be obtained. 



Table I lists the stock numbers of the various 
Fixed-Pressure Regulators, and the gas for which each is to be 
used. 



\2 



TABLE I 
Fixed- Pressure Single-Stage Regulators 



Gas 


Stock Number 


Inlet Pressure 
Gauge - pet 


CGA Inlet 
Connection 


Argon 


806 8044 
806 8054 


4000 
4000 


580 
540 


Helium 


806 8053 


4000 


350 


C02 


806 8055 


2000 


320 


AG75* 


806 8053 


4000 


350 



* 75 Percent Helium and 25 Percent Argon 
NOTE: All outlet connections are 1/4 NPT internal threads. 

1.2 ACCESSORIES 

Accessories are items needed so the Fixed-Pressure Reg- 
ulators can be adapted to suit the particular job requirements. 

A complete line of Flow Adapters (Table n) are available for 
the best gas flow for eachjob. Since gas flow can be "tailored", 
a considerable savings in gas consumption can be realized. 



TABLE II 
Flow Adapters 



Gas 


Gas Flow-cfh 


Stock No . 




Gas 


Gas Flow-cfh 


Stock No. 


Argon 


10 


830 1971 






30 


830 1980 




15 


830 1972 












20 


830 1973 




C0 2 


28 


830 2013 




30 


830 1974 






35 


830 1981 




40 


830 1975 






45 


830 1982 




50 


830 1976 


















AG 75 


15 


830 1983 


Helium 


12 


830 1977 






20 


830 1984 




20 


830 1978 






40 


830 1985 




25 


830 ly79 






50 


830 1986 



13 



Flow Adapters can also be used withanSOl 0281 station valve 
for pipeline service. The pipeline must have a pressure of 
30 psi. 

Figure 2 illustrates the method of connection the Flow Adapters 
to a pipeline. Use an 801 0267 plug and chain assembly to cap- 
off unused outlets. 



FLOW 
ADAPTER 



801 O275 CHAIN 
801 0255 NUT 




GLAND 



Figure 2. Flow Adapter lor Pipeline Service 



Section I). INSTALLATION 



2.1 PRECAUTIONS 

a. These regulators must not be used where rated capacity 
will be exceeded. The regulator will not maintain the required 
delivery pressure under this condition. 

b. Be sure that all connections to the regulator are clean. 
To remove dirt or grease on the regulator and surrounding 
metallic parts, wipe or brush with trichlorethylene. 



CAUTION: 

TRICHLOROETHYLENE WILL HAVE TOXIC EFFECTS 
UNLESS PROPER VENTILATION IS PROVIDED, 
OR IF ALLOWED TO HAVE PROLONGED CONTACT 
WITH THE SKIN. 

c. Never use this regulator for gases other than those for 
which it has been designed and specified. 

d. To clean the cylinder valve outlet, blow-out any foreign 
matter by rapidly opening and closing the cylinder valve. 

2.2 TO CONNECT THE REGULATOR 

a. Observe the precautions listed in the previous paragraph. 

b. Select the flow adapter best suited for your specific needs 
from Table II. It is recommended that a series of adapters be 
kept on hand so that all job requirements can be met. Flow 
adapter markings are shown in Figure 3. 

c. Apply a small amount of pipe compound onto the threads 
of the flow adapter, screw the adapter into the regulator outlet, 
and wrench-tighten. Use the mixture sparingly and apply it to 
the male threads only; take care to prevent the mixture from 
flowing past the end of the first thread. 



GAS FLOW IN CU. FT./HR. 
ON 3O RS.I. INLET PRESSURE 




GAS SERVICE 

AR6 ARGON 
HE HELIUM 
AG7575%HE 25%ARG 
CO, * CARBON DIOXIDE 



Figure 3. Flow Adapter Markings 



d. Tighten the regulator 1 1/8-inch inlet connection nut in 
place with a suitable wrench. 

e. Connect the gas hose to the flow adapter. 

f. Slowly open the cylinder valve. Cylinder pressure is shown 
on the cylinder pressure gauge. 

g. Test all connections for leaks. 
h. Close the cylinder valve. 



Section III. OPERATION 



3.1 TO ADJUST WORKING PRESSURE 

Open the cylinder valve slowly. Sudden changes in pressure 
may damage the internal parts of the regulator. When the 
cylinder valve is completely opened, the required gas flow 
and delivery pressure will be established. 

CAUTION: 

POINT THE CYLINDER VALVE AWAY FROM YOUR 
BODY BEFORE OPENING. 

3.2 TO SHUT DOWN 

NOTE: Perform the following steps when the regulator 
is to be out of use for more than one-half hour. 

a. Close the cylinder valve tightly. 

"b. Open the down-stream valve to drain the line. 

NOTE: When in transit (unless the cylinders are 
mounted on a special truck which holds them securely 
in place) remove the regulator, recap the cylinder, 
and protect the regulator cylinder connection. 



Section IV. MAINTENANCE 



4.1 GENERAL 

Regulators are precision -built instruments and should be han- 
dled as such. Minor repairs such as seat or diaphragm replace- 
ment may be made on the spot by qualified personnel. 

The following are hints for good maintenance practice. 

a. Test the regulator periodically with soapy water to 
locate leaks. 

b. For replacement, use only those AIRCO parts designed 
for your regulator. 

NOTE: Do not, at any time, disturb the sealed-in 
pressure setting screw of the regulator. If this screw 
is tampered with, gas now may not be accurate. 

c. When using a vise or wrench on the regulator, use only 
enough pressure to hold the part. Be careful not to score or 
distort the body, threads, or other parts. 

d. Failure to replace any of the parts may cause a hazard- 
ous condition. 

e. If it is necessary to replace the pressure gauge, the inlet 
nut, and the gland, tin the gauge threads or wrap them with 
teflon tape. Use them sparingly and take care to prevent them 
from going past the end of the first thread. 

f. Before reassembly, always remove dirt or grease, which 
is not readily removable with a lint-free cloth, from the body 
and parts with a cloth dampened with trichloroethylene or 
methylchloroform. Do not allow rubber parts to be exposed 
to either of these solvents for longer than a few seconds, 

CAUTION 



TRICHLOROETHYLENE OR METHYLCHLOROFORM 
(1, 1, 1-TRICHLORETHANE) MAY HAVE TOXIC 
EFFECTS. AVOID BREATHING THE FUMES. 

AVOID PROLONGED CONTACT WITH THE SKIN. 
PROVIDE PROPER VENTILATION. 



17 



4.2 SYMPTOMS OF FAULTY OPERATION 

The following signs indicate faulty operation: the necessary 
repairs should be made immediately. 

a. With no flow through the hose, working pressure in- 
creases steadily above set pressure - indicates a leak across 
the seats. 

b. Continuous discharge of gas from relief valve indicates 
a relief valve failure or seat failure, 

c. Gas leakage from spring case indicates loose or 
damaged diaphragms. 

d. Gas leakage from pressure gauge indicates a damaged 
gauge or a loose connection. If the gauge leaks, it must be 
replaced immediately with a new gauge free of oil and grease. 

e. Gas leakage from inlet connection indicates a dam- 
aged gland or a loose connection. 

f. An excessive drop in indicated cylinder pressure as the 
flow is increased indicates a dirty inlet filter or that the 
cylinder valve is not fully open. If the inlet filter cannot be 
cleaned with compressed nitrogen, replace the gland. 

4.3 DIAPHRAGM REPLACEMENT 

a. Disconnect the regulator from the cylinder. 

b. Mount the regulator vertically with the spring case as- 
sembly UP. If it is more convenient, brace the regulator by 
holding the forged body section with an 11/16-inch wrench, 
and the spring case with a 1 1/4-inch wrench. 

c. Remove the spring case and screw assembly carefully 
by unscrewing it from the regulator body. The adjusting 
screw is preset in the spring case and tension on the adjust- 
ing spring cannot be relieved. 

d. Lift off the spring button, adjusting spring, diaphragm 
plate, and slip ring. 

e. Lift the diaphragm and thrust plate assembly out of the 
regulator body by gripping it by the raised center section. 

f. Replace the diaphragm. Before discarding the old 
diaphragm, pop out the thrust plate by doubling the diaphragm 
over. 

g. Reinsert the thrust plate by pushing the edge of the 
plate under the retaining Up on one side and gradually work- 
ing the lip around over the thrust plate. 



18 



h. Reinstall the diaphragm and thrust plate assembly on 
the regulator body so that the thrust plate is down and the 
sealing surface fits into the groove in the body. 

i. Place the slip ring, diaphragm plate, adjusting spring, 
and spring button (concave side up) on the diaphragm in the 
order named. 

j. Place the spring case on the body and thread together 
carefully. Tighten the spring case with a torque of approx- 
imately 150 inch-pounds. 

k. Connect the regulator to the cylinder. 

4.4 SEAT ASSEMBLY REPLACEMENT 

a. Perform steps a through e, paragraph 4.3. 

b. Remove the seat and retainer assembly with an 11/16- 
inch wrench. Replace the retainer seat. 

c. Remove the thrust pin and seat assembly. 

d. Replace the seat assembly and thrust pin. 

e. Put the small end of the thrust pin in the seat assembly 
carefully. Do not damage the seating surface. 

f. Insert the thrust pin and seat assembly in the marginal 
spring. 

g. Slide the seat and retainer assembly over the thrust 
pin carefully and tighten it in the body with a torque of approx- 
imately 120 inch-pounds. 

h. Perform steps h through k, paragraph 4.3. 

4.5 RELIEF VALVE SEAT REPLACEMENT 

a. Disconnect the regulator from the cylinder. 

b. Mount the regulator body sequrely in a vise or other 
suitable holding device with the relief valve facing UP. 

c. Remove the relief-valve cap by unscrewing it from the 
body. 

d. Lift out the relief-valve spring and the relief-valve stem 
and seat assembly. Replace the seat. 

e. Reinsert the relief-valve stem and seat assembly, relief- 
valve spring, and relief-valve cap in the regulator body. 

f. Connect the regulator to the cylinder. 



19 



I 



r 




PART 3 



AIRCOMATIC GUN 

MODEL AH35-C1 





21 



Is manual provides Installation, operation, and 
intenance information, 

for the Model AH35-C1 AIRCOMATIC 
LI Gun (Fig. 1). Additional information is available 
manuals covering equipment with which the Gun is 
id. 

! DESCRIPTION 

e Gun is a compact, well balanced welding tool with 
itol grip, featuring heavy-duty construction and slm- 
city of design. The complete package includes a 
ipped gun, drive roll housing assembly, flexible 
tft, guide bushing, casing, and liner. With drive 
11 housing in place, the Gun weighs approximately 
3/4 pounds. The nozzle provides adequate gas shield- 
;at low flow rates and is chrome-plated to minimize 
itter buildup. Wire sizes that can be used with the 
n may range from .030 to 1/16-inch aluminum, 
20 to 1/16-inch hard, and 5/64-lnch stranded wire, 
jure 2 provides dimensions, and Table I pertinent 
aracteristics, of the Gun. 

J ACCESSORY IQUIPMINT 

ims required to adapt the Gun for any particular 
> are called accessories. These include contact 
5es, inlet and outlet guide bushings, and drive rolls 
suit the type and size of welding wire used, as shown 
Figure 8 of Section n. 

i AUXILIARY EQUIPMENT 

ixiliary equipment comprises items, in addition to 
cessories, required to complete a typical welding 
stallation. Such equipment includes: goggles, 



Characteristics 


Specifications 


Continuous duty rating 


400 amps Argon 


DC reverse polarity 


550 amps CO 2 


Wire types and diam- 
eters (inches) 

Aluminum and 
Magnesium 

Stranded 
Hard 


.030, 3/64, 1/16 

5/64 

.020, .025, .030, .035, 
.045, 1/16 


Cooling medium 


Water 


Cooling water flow 
rate 


2 pints per minute at 
30 psi (75 psi max. ) 


Hose and cable lengths 
(nominal) 


10 feet 



Table n. Optional Equipment 



Table II not applicable 




Tigute 1. Model AH35-C1 Pull Gun 



I 



22 




ABLES, CASING 
BLE SHAFT) 



HOSE . SERVICE 
LINE CORD 
APPROX. 10 FT. LG. 




source does not contain a primary contactor. 



Figure 2. Dimensions 



Section II. INSTALLATION 



RAL 

:ion covers installation of the Gun only, for 
1 instructions refer to the applicable feeder, 
and power source manuals. 

ICKING AND INSPECTION 

he Gun carefully. Inspect the unit, cables, 
3. Operate the Gun trigger to make sure that 
. Inspect visible surfaces of the drive roll 
Dr damage. Place the housing on the stripped 
ipect the casing assembly, liner, and outlet 
hing. 



AL11NG JOG SWITCH 

NOTS: The Model AHF-E1 Feeder 
includes a jog switch which may be 
installed in the Gun handle as fol- 
lows (Fig. 3): 

ress down lock button (Fig. 4) on right side 
id slide off drive roll housing. 

nscrew and remove nozzle from Gun. 
nscrew barrel lock nut. 

emove left screws from backplate and drive 
ing retainer, 

ay Gun on its right side. Remove the four hex- 
sad cap screws which hold the left-hand han- 



f. Lift left-hand handle off carefully. 

g. Remove plug near the handle bottom. 

h. Connect lead of jog switch to terminal on trig- 
er switch which has two leads. 



LOCK PIN 

BARREL AND SPRING 
LOCK NUT \ BACKPLATE 



DRIVE ROLL 
HOUSING RETAINER 




JOG 

SWITCH 

NUT 



.(SOLDER 
HERE) 



JOG SWITCH 
MOUNTING PLATE 



Figure 3. Installing Jog Button 



SLIDING 

LOCK 
BUTTON 




a. Press down lock button (Fig. 4) on right side 
of Gun. Slide off drive roll housing. 

b. Remove screw on right side of drive roll hous- 
ing (Fig. 5). 

c. Remove protective caps from the flexible shaft 
and push square shank-end into casing (Fig. 6) to ex- 
pose the tapped fitting at the other end. 



Figure 4. Removing Drive Roll Housing 



i. Solder black wire control cable assembly 
taped when not used) to open terminal of jog switch. 

j. Check action of the jog switch. 

k. Fit mounting plate of jog switch into its retain - 
ng groove at base of right-hand handle assembly. 

1. Check the trigger and its switch for proper op- 
iration. 

m. Make sure spring on drive roll housing lock 
ind springs in trigger have not slipped out of position. 

n. Fit left-hand handle over end of lock pin and 
ipring and onto right-hand handle assembly. Align 
iiounting holes. 

o. Secure these assemblies with hardware re- 
noved in step e. 

p. Tighten jog switch nut. 

q. Screw on barrej. lock nut and tighten, 
r. Screw on nozzle and tighten. 

s. Slide and lock drive roll housing onto Gun. Ad- 
just position of drive roll housing retainer if neces- 
sary. 



FLEXIBLE 
SHAFT CASING 





DRIVE ROLL 
HOUSING 



Figure 6. Removing Anchoring Screw for Flexible 
Shaft Casing 




Figure 5. Pushing Flexible Shaft into Casing 



Figure 7. Inserting Tapped End of Flexible Shaft into 
Drive Roll Housing 

d. Insert left-hand tapped end of flexible shaft into 
top hole of drive roll housing (Fig. 7) to engage end of 
wormshaft within housing. 

e. Turn housing counterclockwise so that worm 
will screw into left-hand thread of flexible shaft. Hand 
tighten. 

f. Slide casing of flexible shaft into housing hole 
as far as it will go. 

g. Secure casing with screw removed in step b. 
h. Straighten flexible shaft. 

NOT: Do not lock drive roll housing 
on Gun until wire and wire guide fit- 
tings are installed. 



MAKE SURE ALL POWER IS OFF. 

water-out and cable assembly, water-in hose, 
e, and control cable of the Gun to feeder ac- 
to instructions in feeder manual. 



IE GUIDE FITTINGS IN DRIVE ROLL HOUSING 

vire guide fittings (Fig. 8) in drive roll hous- 
ollows: 



b. Back off adjusting set screw (Fig. 9) on right- 
hand disc of drive roll housing to relieve pressure on 
conical roll shaft. 

c. Insert conical roll into end of conical roll shaft 
(Fig. 10). 

d. Hold conical roll depressed. Insert grooved roll 
into end of grooved roll shaft. Release conical roll. 

e. Lift casing catch and install inlet guide bush- 
ing in bottom holeof drive roll housing (Fig. ll). Re- 
lease catch. 



CONTACT TUBE 



OUTLET GUIDE 
SLEEVE 



2389 3904 
0-RING ONLY 

OUTLET GUIDE BUSHING 
INCLUDES O-RING 



INLET GUIDE BUSHING 




* WHEN FEEDING EXTRA HARD WIRES, 
USE KNURLED DRIVE ROLL 23640131. 



VIEW- A- A 





WIRE 


SIZE 


WIRE 
GUIDE 
KIT 


CONTACT 
TUBE 
(5/Kit) 


OUTLET 
GUIDE 
SLEEVE 
(2/Kit) 


INLET 
GUIDE 
BUSHING 
(with O-Rtng) 


INLET 
GUIDE 
BUSHING 


* 

CONICAL 
ROLL 


GROOVED 
ROLL 


d 


. 020 & . 025 


2354 0124 


2360 2136 


2360 2274 


2360 1074 


2360 2273 


2360 1825 


2360 1827 


d & Alum. 


.030 


2354 0125 


2360 2136 


2360 2274 


2360 1075 


2360 2270 


2360 1825 


2360 1829 


d 


.035 


2360 2115 


2360 2275 


2360 1075 


2360 2270 


2360 1825 


2360 1829 


rdnum 


3/64 


2354 0126 


2360 2115 


2360 2275 


2360 1086 


2360 2271 


2360 1825 


2360 1830 


d 


.045 


d & Alum. 


1/16 


2354 0127 


2360 2135 


2360 2276 


2360 1076 


2360 2272 


2360 1825 


2360 1832 


nded 


5/64 


2354 0128 


2360 0301, 


2360 2313 


2360 1076 


2360 2272 


2360 1825 


2360 1832 







Figure 8. Wire Guide Fittings 



25 



SET eW ON 

SPRING -BACKED 

ROLL SHAFT 



DRfVE 

ROLL 

HOUSING 




Figure 0. Adjusting Srtusrw? for Conical Roll Shalt 



.CASING 

'CATCH 

GROOVED 
ROLL 




CONICAL 
ROLL 



V 

Fegf id. totMrttaf Driw Boll in ffliaft 



CAUTION 

MAKE SURE ALL POWER IS OFF. 
Install the casing assembly as follows: 

a. Insert liner (Fig. 12) into casing assembly when 
aluminum wire is to be used. 

NOTI: Liner may also be used with 
hard wire. 



I 




Figure 11. fulfilling Casing Liner 



b. Insert casing outlet guide bushing into the 
feeder as explained in the feeder manual. 

c. Arrange casing so it is reasonably straight. 
Slowly ease welding wire from feeder spool into and 
through casing until about 8 inches emerges at front 
end of casing. 

d. Thread nut end of casing into feeder. 

e. Turn drive roll housing of Gun upside down. 
Insert wire protruding from casing into drive roll hous- 
ing hole, through inlet bushing, and up to conical and 
grooved roll (Fig. 13). 



INLET 
GUIDE BUSHING 




LATCH 
Figure 11. Install^- Ms* Quids Buohing 



INLET GUIDE 
BUSHING 

WELDING 
WIRE 



CASIN6 



GROOVED 
ROLL 



CONICAL 
ROLL 




Figure 19. Latehiai Caning to Driva Roll Housing 



26 



lur ins uuiiei guide Dusnmg. 

g. Pus-h casing Into housing until latch engages in 
ing groove. 

h. Release conical roll after making sure that wire 
roperly seated in grooved roll. 

i. Slip drive roll outlet guide bushing (Fig. 8 ) 
r protruding wire and seat in crossbar opening. 

j. Turnadjusting setscrew (Fig. 9) slowly clock- 
; until conical roll presses on wire within grooved 
. Compression should be just enough for positive 
3 drive. 

INSTALLING WIRE GUIDE FITTINGS IN GUN 
BARREL 

all wire guide fittings selected in paragraph 2. 6 
the Gun barrel as follows: 

a. Insert a 1-3/16-inch long outlet guide sleeve 
. 14) into liner retainer of Gun. Push sleeve all 
way in until end is at base of retainer counterbore 
. 15). (Slots in retainer hold the sleeve in place. ) 




Figure 14. Installing Outlet Guide Sleeve in Gun 



b. Unscrew and remove nozzle from Gun. 

c. Pass end of wire protruding from drive roll 
housing (Fig. 16) into liner retainer and outlet guide 
sleeve. Slide drive roll housing onto stripped Gun un- 
til housing is locked. 



OUTLET GUIDE 
SLEEVE 



LINER RETAINER 



CONTACT TUBE 





DRIVE ROLL OUTLET 
GUIDE BUSHING 
MOUNTED IN DRIVE 
ROLL HOUSING 



Figure 15. Final Position of Wire Guide Fittings in Gun Barrel 



27 



OUTLET 

GUIDE 
BUSHiNG 




Figure 16. Sliding Drive Roll Housing with Wist oato 
Gun 



BARREL AND 
TRANSFER 
BLOCK ASSY. COLLET 



COLLET CONTACT 
NUT / TUBE- 





I 



Figure 17. Installing Contact Tube 



Figure 18. Nozzle-to-Contact Tub Distance 

d. Remove collet nut from Gun barrel (Fig. 17). 

Won. 1 Do not let collet roll away 

e. Slide collet, then collet nut onto contact tube. 

f . Slide contact tube with collet and nut onto wire 
protruding from Gun. Push contact tube into barrel 
until it touches liner retainer (Fig. 15). 

g. Screw collet nut over collet onto barrel end. 
Use wrench supplied with Gun to tighten. 

h. Screw nozzle onto barrel and tighten. The noz- 
zle-to-contact-tube distance should be approximately 
3/16-inch (Fig. 18), if all fittings have been properly 
installed. 



Section III. OPERATION 



3.1 SAFETY RQUIREMINT 

Comply with all ventilation, fire, -and other safety re- 
quirements for welding as established for industrial 
applications. Reference as applicable: Safety in Elec- 
tric and Gas Welding and Cutting Operation, American 
Standard Association Bulletin Z49. 1, 1958, and Rec- 
ommended Safe Practices for Inert-Gas Metal- Arc 
Welding, American Welding Society Bulletin A6. 1, 



Because of infrared radiation emitted by the high-in- 
tensity arc in AIRCOMATIC welding methods, flash 
goggles (medium shade 1306 2101) are recommended 
in addition to helmet for the operator and nearby per- 
sonnel. 

Do not weld in the presence of even minute amounts of 
vapors from chlorinated solvents (such as carbon tetra- 
chloride or trichlorethylene). Ultraviolet light from 
the electric arc can break down the vapors to form 
phosgene, a poisonous gas. 



The welding wire (electrode) and all metal parts in 
contact with it are electrically energized while weld- 
ing. Periodic inspection of Gun and cables for broken 
insulation, water leakage and other electrical hazards 
is essential. 

CAUTION 

WHENEVER STEPS ARE TAKEN TO 
REMOVE AND REPAIR SUCH HAZ- 
ARDS, PLACE ALL POWER CON- 
TROLS OFF. DISCONNECT ALL 
ELECTRICAL CABLING FROM 
POWER SOURCES. 

3.2 PRE.WIU3 CHECKLIST 

Check the Gun as follows: 

a. Drive roll housing assembly locked on stripped 



Gun. 



b. All hose and cable assemblies tight. 



I 



Velding wire protrudes from Gun nozzle. 



e. .ria.ce uun aside wnere proiruaing wire eiec- 
trode cannot touch any metallic surface. 



IMINARY PROCEDURES FOR GUN OPERATION 

NOTE: If equipment has not been in 
recent use, point Gun toward floor 
and press trigger for a short inter- 
val to purge the gas and water lines. 

ontrols on equipment in the system as instruct- 
lipment manuals. 

ir a new welding operation begins, perform a 
.don metal similar to the workplace. Proceed 

if a: 



31amp welding power source cable (negative) 
siece. 



Gun at trial piece to be welded, holding 
few inches away. 

f operation is set for SCRATCH START, rub 
p end of welding wire against trial piece until 
arted; if set for RUN-IN START, arc should 
soon as welding wire contacts trial piece. 

Vhen arc starts and gas flows, vary distance 
lozzle from trial piece to determine approxi- 
low far from trial piece Gun operation pro- 
e best results. 

lelease trigger but hold Gun over weld puddle 
it-weld gas flow stops. 

Set Gun aside where protruding wire electrode 
:mch any metallic surface. 



DING OPERATION 

>rm a welding operation with the Gun, proceed 
vs: 

Mm Gun atworkpiece. Keep nozzle at distance 
tisfactory during trial weld. 

Pull back and hold trigger to keep wire feeding 
usly into arc. (Weld puddle will be protected 
ding gas as puddle solidifies. ) 

Release trigger to stop welding, but hold Gun 
position for short interval until post-weld gas 
wing. 



3.5 SHUTDOWN PROCEDURES 

Environmental conditions and safety requirements will 
determine the extent of equipment shutdown between 
operations. If temperature may fall below the, freezing 
point, perform ALL the following steps, otherwise be- 
gin with step e. 

a. Turn OFF welding power source. 

b. Turn OFF water and disconnect water supply 
hose. 

c. Press Gun trigger to open water solenoid. 

d. Disconnect water-in hose and blow out water 
lines with compressed air. 

e. Place all (remaining) power controls OFF. 

f. Disconnect power cable from the 115 volt ac 
source. 

g. Turn OFF gas. 

h. Place Gun in safe location. Coil or drape hose 
and cables without sharp bends. 

3.6 PRINCIPLES OF OPERATION 

When the Gun trigger switch is closed, it operates a 
main control relay which, through other relays, com- 
pletes the circuits to the weld current, gas and water 
solenoids, water pressure switch, and time -delay re- 
lay (which provides a timed interval of post-weld gas 
flow). Simultaneously, a motor-drive relay circuit is 
energized to run the feeder motor. This motor, drives 
a wormshaft through the flexible shaft within the drive 
roll housing locked to the Gun. 

The wormshaft, in turn, drives a geared shaft on each 
side, which turn in opposite directions. One shaft end 
contains agroovedroll fitting in which the welding wire 
is seated; the other contains a conical roll which pro- 
vides pressure against the wire in the grooved roll. 
Hence, the welding wire is pulled through theGun cas- 
ing from a spool in the feeder. 

Welding current from the welding power source is ap- 
plied to the system through a reverse polarity circuit. 
This consists of a secondary weld contactor (if needed), 
a welding current cable attached to the Gun barrel, the 
welding wire (consumable electrode) within the barrel, 
the workpiece, and the cable from the power source 
clamped to the workpiece. 



29' 



s section covers preventive maintenance, mspec- 
and service and repairs required to keep the Gun 
ninimum standards for efficient operation. 

ventive maintenance consists of cleaning, tighten- 
and minor repairing designed to prevent down-time 
quipment for major service and parts replacement. 
30 day intervals and, whenever the wire guide fit- 
is are replaced, inspect and service the Gun as 
ows: 

CAUTION 

MAKE SURE ALL POWER IS OFF. 

a. Clean Gun exterior. 

b. Unscrew and remove nozzle. 

c. Remove accumulated spatter from nozzle. Be 
e threads are clean and in good condition. 



wire. 

e. Make sure mating surfaces of Gun and housing 
are clean. If necessary, use compressed air to re- 
move any dust or dirt. 

f. Make sure gas orifices at front of Gun barrel 
are not clogged. 

g. Checkfor damage on all hoses and cables. Make 
sure all connections are tight. 

h. Insert protruding wire of drive roll housing into 
liner retainer of Gun barrel. Slowly slide housing into 
place on Gun until it locks in. 

i. Screw nozzle onto Gun. Hand tighten. 

]. Turn power ON. Operate Gun with trigger for 
a short interval to ascertain satisfactory operation. 
Use jog button, if attached, to test wire feed mechan- 
ism. 



Table III. Welding System Troubleshooting 



SYMPTOM 



PROBABLE CAUSE 



REMEDY 



No welding arc with power 
ON and Gun trigger de- 
pressed. 



No gas flow with power ON 
and Gun trigger depressed. 



No water flow with power 
ON and Gun trigger de- 
pressed. 



a. Welding power source 
OFF. 

b. Contactor trouble. 

c. Defective cable. 

d. Malfunction in Gun. 

e. Malfunction in feeder. 

a. Gas source OFF. 

b. Clogged line. 

c. Malfunction in Gun. 

d. Malfunction in feeder. 

a. Water source OFF. 

b. Clogged line. 

c. Malfunction in Gun. 

d. Malfunction in control. 



a. Turn ON. 

b. Check and repair. 

c. Repair or replace. 

d. See Table IV. 

e. See feeder manual 

a. Turn ON. 

b. Repair or replace 

c. See Table IV. 

d. See feeder manual. 

a. Turn ON. 

b. Repair or replace. 

c. See Table IV. 

d. See Control Manual. 



30 



pressed. 



No gas flow with power ON 
and Gun trigger depressed. 



No water flow with power 
ON and Gun trigger de- 
pressed. 



Improper or no wire feed 
with power ON and Gun 
trigger depressed. 



Improper or no wire feed 
with power ON and jog 
button depressed. 



Drive roll housing does not 
lock on Gun. 



b. Defect in cable of water - 
out and cable assembly. 

c. Wire within Gun discon- 
nected. 

a. Clogged or pinched gas 
line on Gun. 

b. Gas orifices on Gun 
barrel stopped up. 

a. Clogged water hoses. 

b. Blockage within barrel 
and transfer block as- 
sembly. 



a. Break in welding wire. 

b. Flexible shaft mal- 
function. 



c. Defective wire guide 
fitting in drive roll 
housing assembly or 
Gun barrel. 

d. Defective trigger wire 
or connection within 
Gun. 

e. Defective trigger switch. 

f. Defective trigger switch 
compression spring. 

a. Check causes (a) thru 
(d), above, for no 
wire feed with trigger 
depressed. 

b. Defective jog button. 

c. Defective switch or 
switch wiring. 

a. Defective compression 
spring. 

b. Defective drive roll 
housing lock. 

c. Shifted or damaged drive 
roll housing retainer. 

d. Defective backplate or 
screws project. 



b. Check continuity and 
replace if necessary. 

c. Disassemble Gun and 
repair. 

a. Repair or replace. 



b. Remove nozzle and 
clean. 

a. Repair or replace. 

b. Disconnect water 
hoses and blow out 
with compressed 
air. 

a. Check and repair. 

b. Check for proper 
coupling at each end, 
or replace. 

c. Check, repair or 
replace. 



d. Check, repair or 
replace. 



e. Replace. 

f. Replace. 

a. Perform remedies 
(a) thru (d), above 
for no wire feed with 
trigger depressed. 

b. Replace. 

c. Repair or replace. 

a. Replace. 

b. Replace. 

c. Reposition or replace. 

d. Adjust or replace. 



31 



CAUTION 

MAKE SURE ALL POWER IS OFF. 

a. Push in lock button on right side of Gun. Slide 
off drive roll housing. 

b. Unscrew and remove nozzle from Gun barrel. 

c. Pull Length of wire out of Gun barrel. 

d. Actuate casing latch. Pull casing out of drive 
roll housing. 

e. Remove casing from feeder. 



h. Insert protruding wire ol drive roil housing as- 
sembly at Gun into liner retainer. Slowly slide housing 
into place on Gun until it locks in. 

i. Screw nozzle onto Gun. Hand tighten. 

j. Turn power ON. Operate Gun with trigger (and 
jog button, if installed) for a short interval to ascer- 
tain that it operates satisfactorily. 

4.3 TROUBLESHOOTING 

When a malfunction occurs in the welding system, re- 
fer to Table III to determine whether the trouble can be 
confined to the Gun. Then troubleshoot the Gun in ac- 
cordance with Table IV. 



I ** , f fa jjt ST $j f ^ f J f ^J T 

^w^*" ' 

,/ ^ '^'^"i{ jfWff /f* /' I 




AIRCOMATIC 
PUSH-PULL WIRE FEEDER 



MODEL AHF-E1 




33 




Figure L Model AHF - 1 Push- Pull Wire Feeder 



Section I. INTRODUCTION 



al covers the description, installation, oper- 

maintenance of, 

the Model AHF-E1 AIRCOMATIC Push- 
e Feeder (Fig. 1) used in M1G welding. 

IPTION 

atile unit feeds welding wire and monitors 
arrent, cooling water, and shielding gas to 



an AIRCOMATIC gun. It can be used with either a 
push or pull type. The carriage supports all the feeder 
components. The motor drives the welding wire through 
the gun. The drive rolls drive wire when a push gun is 
used. The reel deck supports the hub, brake, and 
brake adjustment device. The strain relief relieves 
the strain on hoses, casing, and flexible shaft. The 
cover protects the mechanisms. See Figure 2 for 
dimensions. 



NOTE: ALL DIMS. ARE APPROX 




9 1/8" 



Figure 2. Dimensions 
35 



Section II. 

AUXILIARY EQUIPMENT 

iliary equipment comprises items, in addition to 
sssories, required to complete a typical welding 
allation. Such equipment includes: goggles, helmet, 
r es, welding cables, gas and water hoses and fit- 
s, regulator and flowmeter, shielding gas, weld- 
wire, a push or pull type welding gun, a Model 
2-B Control, a power source, and a secondary 



III in Section II is included to aid in the local procure- 
ment or fabrication of needed welding cables. 



Section ||. INSTALLATION 



GENERAL 

s section covers installation of the Feeder and its 
rconnection with the components needed to operate 
} welding system. 

UNPACKING, INSPECTION, AND ASSEMBLY 

iack the Feeder carefully. Inspect the unit * 



NOTE: A jog button is supplied with 
the Feeder for attachment to water- 
cooled guns. Refer to the water- 
cooled gun manual for installation 
instructions. 

STRAIN RELIEF KIT INSTALLATION 

he strain relief (Fig. 3) is to be used, screw the 
me onto the bottom of the carriage with the four 
ews provided in the kit. 



SITE SELECTION 

ect a location for the Feeder so that it will be easy 
idjust the wire feed speed dial (Fig. 3). Position 
Feeder to avoid kinks or sharp bends in the hoses 
. cables. If practical, allow room for full opening 
the hinged cover (Fig. 3) and turning the unit on 
side for removal of the bottom cover and inspection 
:he under-carriage components. 

INSTALLING WIRE GUIDE FITTINGS 

ect the inlet guide bushing, knurled or conical drive 
1, and grooved drive roll suitable for the wire type 
I size to be used as indicated in Table I. 

NOTE: If the Feeder is to be used 
with a pull gun, do not install drive 
rolls, but perform steps a and e. 



a. Unlock and open hinged cover, 

b. Insert the conical drive roll into the upper roll 
shaft. 

c. Hold cam handle (Fig. 4) depressed to raise 
conical drive roll in upper roll shaft. 

d. Insert the grooved drive roll into the lower roll 
shaft. Release cam handle. 

e. Insert inlet guide bushing into drive roll housing 
(Fig. 4). 



TABLE I 
Wire Guide Fittings 



Wire Size 


Inlet Guide 
Bushing Assy, 
with "O" Ring 


Drive Roll 


Conical 


Grooved 


Hard .035 
Hard . 045 
Hard 1/16 
Hard 5/64 
Hard 3/32 


2360 0883 
2360 0883 
2360 0884 
2360 1714 
2360 0885 


2360 1700 
2360 1700 
2360 1700 
2360 1700 
2360 1700 


2360 1702 
2360 1702 
2360 1703 
2360 1704 
2360 1705 


Al. 3/64 
Al. 1/16 
Al. 3/32 
Al. 1/8 


2360 0883 
2360 0884 
2360 0885 
2360 0886 


2360 1701 
2360 1701 
2360 1701 
2360 1701 


2360 1702 
2360 1703 
2360 1705 
2360 1706 


Stranded 
5/64 


2360 1714 


2360 1701 


2360 1704 



36 




1 %! 



Figure 3. Wire Feeder, Front View 



.IING AND THREADING WIRE 

I thread the welding wire in the Feeder as 

k and open hinged cover. 
t wire size and type, 
lever of hub assembly (Fig. 5) in vertical 

'ire spool onto hub. Position it so that spool 
:wise as wire pays out. 

:e hub flange pin with hole in spool. Place 
i horizontal position. 

ailing a pull gun, refer to the gun manual for 
lation. Be sure PUSH-PULL switch is in 
tion after wire is installed bet ween pull- gun 



g. If installing a push gun, place the PUSH-PULL 
switch in PULL position and perform the following 
steps. 

h. Back off adjustment knob on drive roll housing 
(Fig. 4) a few turns counterclockwise. 

MOTS: Never turn the adjusting set- 
screw of the grooved roll shaft. This 
is factory-set, and any disturbance 
may cause misalignment of the shaft 
and roll, requiring special gauges 
for correction. 

i. Lift end of wire from spool. Clip the wire to re- 
move the sharp bend. Smooth the cut end to prevent 
snagging. Straighten the wire, but keep it taut so that 
it cannot loosen on spool. 

j. Holding cam handle depressed, pass wire through 
inlet guide bushing, between conical and grooved rolls, 



37 







ROLL 

l - 

Figure 4. Wire Feeder, Inside View 




ind out about an inch through the casing inlet guide 
nishing housing (Fig. 6). 

k. Release cam handle and gently turn adjustment 
cnob clockwise to add only sufficient pressure of 
:onical roll against wire to allow rolling friction for 
'ceding withcmt deforming. 




Fifur S. Hub AastmWy 



NQTi: The adjustment knob, once 
properly set, need not be readjusted 
unless wire of different size or qual- 
ity is to be threaded. 

1. Wind the spool counterclockwise to take up slack 
between the spool and drive rolls. 

IMPORTANT: 

1. Do not push wire back through the 
drive rolls. The wire may kink. 

2. If the wire end is not straight, cut 
off the bent part and remove burrs to 
prevent jamming in the casing. 

m. Pass the end of the gun casing through the casing 
retainer (Fig. 6). 

n. Fit the casing through the drive roll housing near 
the drive rolls so welding wire enters the end of the 
casing inlet bushing. 

o. Screw the retaining nut of the casing firmly into 
the casing retainer. 

p. Check that the casing inlet bushing is as close, 
to the drive rolls as possible without touching and 
centered so wire cannot scrape against it. Align- 



38 



RETAINER 
HOUSING 



GUN 
CASING 




CASING RETAINER 
HOUSING SCREW 
(2) 



CASING 



CONICAL ROLL 



GROOVED ROLL 



CASING INLET 
BUSHING 



CASING 

RETAINER 

NUT 



CASING 

RETAINER 

SCREW 



Figure 6. Drive Roll Housing 



bushing with the drive rolls may require 
end of the casing assembly horizontally 
#ay from the drive rolls and/or shifting 
etainer housing. If any of these adjust- 
scessary, proceed as follows: 

at the casing retainer screw sufficiently to 
Sing to slide forward or backward. Bring 
-ilet bushing close to the drive rolls and 
? screw. 

the casing retainer housing screws, if re- 
Lcientlyto allow movement of the housing, 
ing the drive rolls from the side of the 
top of the casing inlet bushing should be 
d between the upper and lower drive rolls. 
e screws. 

TING FEEDER IN SYSTEM 

=der is interconnected (Fig. 7) withaCon- 
; power source, gun, and (if power source 
ntain a primary contactor) a secondary 
rhis requires two water hoses (water- 
mly), a gas hose, a multi- conductor cable, 
tor-to-feeder cable (or power source to 
> of the water 'hoses (water-out-to-relay) 
ti- conductor cable are supplied in a hose 
t available in three sizes as shown in Table 
r water hose is a customer-furnished, 



5/16-inch hose that connects the Feeder to the water 
supply. The gas hose is a customer-furnished, 5/16- 
inch hose that connects the Feeder to the gas supply. 

b. If supply water pressure exceeds 75 psi, install 
a water pressure regulator at inlet end of water hose. 

c. If continuous water cooling for severe service 
conditions is required, refer to control manual for 
necessary re-connection of the control cable leads. 

NOTE: For adequate cooling, water 
must flow at the rate of at least two 
pints per minute requiring a pres- 
sure of about 30 psi. The gun will 
not operate unless the water pres- 
sure switch (factory- set at 25 psi) 
is closed. However, in unusual 
cases, a clogged or pinched water 
line might generate enough back 
pressure to close this switch even 
with insufficient cooling water in the 
system. For this reason keep end of 
water drain hose visible at all times. 

2.8 CONNECTING GUN TO FEEDER 

a. Attach the gun casing as explained in paragraph 
2. 6 of the gun manual. 



39 



V 



GAS SUPPLY SOURCE 




WATER SOLENOID 



WATER PRESSURE 
SWITCH 

WATER FILTER 



PUSH -PULL 
TOGGLE SWITCH 

LOCAL-REMOTE CONTROL 
TOGGLE SWITCH 



WATER SUPPLY 





WATER OL'T TO 
CURRENT RELAY 



MULTI-CONDUCTOR CABLE 



^WELDIMG CABLE TO SECONDARY 
CONTACTOR OR PLUS (+) TERMINAL 
OF POWER SOURCE 



Figure 7. Interconnection Diagram 

M-0 




CASING FOR 
WELDING WIRE 



GAS 



WATER -OUT 
CABLE ASSY 



CONTROL CABLE 



WATER- IN 



Figure 8. Connecting Gun 




FRAME 



CLAMP 




SCREW, 8-32 X 1-1/8 
NUT.8-32 



Figure 9. Anchoring Cable and Hoses on Strain Relief 
if] 











15 


2360 2203 


2360 2205 


2360 1196 


50 


2360 2203 


2360 2206 


2360 0979 


100 


2360 2257 


2360 2284 


2360 1301 



TABLE III 
Cable Size Selector Guide 





Feet 


Amps. 


50 


75 


100 


125 


150 


175 


200 


225 


250 


300 


350 


400 


100 


2 


2 


2 


2 


1 


1/0 


1/0 


2/0 


2/0 


3/0 


4/0 


4/0 


150 


2 


2 


1 


1/0 


2/0 


3/0 


3/0 


4/0 










200 


2 


1 


1/0 


2/0 


3/0 


4/0 


4/0 












250 


2 


1/0 


2/0 


3/0 


4/0 
















300 


1 


2/0 


3/0 


4/0 


















350 


1/0 


2/0 


4/0 




















400 


1/0 


3/0 


4/0 




















450 


2/0 


3/0 






















500 


2/0 


4/0 























b. Make all other gun connections as shov/n in Fig- 
ure 8. 

c, Anchor cables and hoses and flexible shaft on 
strain relief (Fig. 9} to prevent straining at connec- 
tion points to the Feeder as follows: 

1. Fasten hoses, casing and flexible shaft, if any, 
side-by-side in order of decreasing hose diameter 
u/.der nose of frame. Leave a small amount of slack. 



2. Place clamping bar under this cluster. Apply 
screws and wing nuts. 

3. Tighten screws only sufficiently to hold the 
cluster into place. 

fMPORrANT: Be careful not to flat- 
ten the hoses excessively. Excessive 
clamping may hinder flow through 
the hoses. 



Section 9ii. OPERATION 



3.1 SAFETY REQUIREMENTS 

Comply with all ventilation, fire and other safety re- 
quirements for welding as established for industrial 
applications. Reference as applicable: 

a. "Safety in Electric and Gas- Weldjng and Cutting 
Operaiion". . . American Standards Association: 
Bulletin 249. 1, 1556. 



b. "Recommended Safe Practices 
Metal- Arc" Welriing". . . American 
Bulletin AS. F, ~ 



for Inert-Gas 
Welding Society? 



Because of infrared radiation emitted by the high- in- 
tensity arc in AIRCOMATIC welding methods, flash 



goggles (medium- shade 1306 2101) are recommended 
in addition to helmet for the operator and near-by per- 
sonnel. The welding wire (electrode) and all metal 
parts in contact with it are electrically energized while 
welding, requiring periodic inspection of cables for 
broken insulation, water leakage, and other electrical 
hazards. 

CAUTION 

WHENEVER STEPS ARE TAKEN 
TO REMOVE AND REPAIR SUCH 
HAZARDS, PLACE ALL POWER 
CONTROLSOFF AND DISCONNECT 
ALL ELECTRICAL CABLING FROM 
POWER SOURCES. 



re feed speed dial, a pre-weld checklist, an 
ing sequence (Fig. 10) and inspection during and 
peration. As additional aids toward understand- 
is system, a schematic diagram (Fig. 11) and 
; diagram (Fig. 12) are included at the end of 
action. 



3.3 SETTING WIRE SPEED DIAL 

Manually set the desired wire feed speed on the dial 
of the wire feed speed dial (Fig. 3), as follows: 



TABLE IV 
Functions of Controls and Selected Electrical Components 



Control or 
Component 



Symbol 



Function 



Wire Feed Speed 
Potentiometer 
Dial (Fig. 3) 



PUSH-PULL 
Switch (Fig. 4) 



LOCAL- REMOTE 
Switch (Fig. 4) 



Rill 



R113 



SW107 



SW103 



Tachometer- 
Generator (Fig. 4) 



Solenoid; 

Brake (Fig. 11) 



Gas (Fig. 12) 



Water (Fig. 12) 



TG101 



BS101 



GS101 



WS101 



For manual setting of desired wire feed 
speed. Rated: 0-20, 000 ohms, 5W, con- 
tinuously variable. 

Functions in parallel with Rill when PUSH- 
PULL switch SW107 is in PULL position to 
adapt Rill for pull operation. 

PUSH position (for push guns) opens brake 
solenoid circuit to apply drag on wire reel. 
PULL position (for pull guns) closes brake 
solenoid circuit to retract brake and remove 
drag. 

LOCAL position switches Wire Feed Speed 
Potentiometer (Rill) into motor control 
circuit so that speed can be hand- set at 
panel dial. 

REMOTE position switches Rill out of and 
Remote Control (R112) into motor circuit 
so that speed can be set on the remote 
control. 

Produces electrical equivalent of existing 
motor speed for motor control circuit in 
control unit. 

Retracts brake during pull operation of 
Feeder when energized by pull gun trigger. 
Upon release of trigger, brake engages. 

Allows gas flow during push or pull opera- 
tion of Feeder when energized by gun 
trigger. 

Allows water to flow during push or pull 
operation of Feeder when energized by 
gun trigger. 



CR104 P. U. 
1 



CR105 P. U. 
(motor runs) 

(wire feeds) 



Release SW106 
l 



CR105 D. O. 
(motor stops) 
(wire feed stops) 



BS101 P. U. * 
(brake releases) 



BSIOID. o. * 

(brake applied) 



b. Wire Feed Selector in "Run-in Start" Position 



SW102 in run-in start position 
SW104 (pressure switch closed) 
Throw SW101 (wait 30 seconds) 

Pull SW105 (weld trigger) 
CR103 P.U. 



TDR101 P. U. 

GS101 P. U. WS101 P.U. 
(gas and water flow) 



WC. P.U. 
I 
1 
1 

Wire touches work 
arc established 



CR105 P. U. 

(motor runs) 

(wire feeds) 

1 



BS101P. U. * 
(brake released) 



Wire Feed Selector in "Scratch Start" Position 

SW102 in scratch start position 
SW104 (pressure switch) closed 
Throw SW101 (wait 30 seconds) 

4 
Pull SW105 (weld trigger) 

CR103 P.U. 
j . ,. I 

TDR101 P.U. 

I 



* 4 

GS101 P. U. WS101 P. U. 

(gas and water flow) 



WC. - P. U. 

Scratch wire on work 
CR101 P. U. 

arc established 

CR102 P. U. 

l 



d. End of Weld Sequence 



CR105 P. U. 
(motor runs) 
(wire feeds) 



Release SW105 (weld trigger) 

CR103 D. O. 
L 



TDR101 D. O. 
(starts timing) 

1 

TDR101 Times Out 

4" J 
GS101 D. O. SW101 D. O. 
(gas and water stop flowing) 

"Onlv if SW107 in PULL (closed) position. 



1 
CR105 D. O. 

(motor stops) 
(dynamic braking) 
(wire stops feeding) 



BS101 P. U. * 
(brake released) 



BS101 D. O. 
(brake applied) 



Figure 10. Sequence Chart, Wire Feeder Operation 




IOA 



TS 103 T 101 P TS 103 
- 



' liZ T IO VV T5 107 TS 101 WS | 01 T5IO SOIOJ T5IOZ 




Figure 11. Schematic Diagram 







TSI06 


(RECTIFIER) 

*' TSIOS 
VIOZ T 102S6 C577 

SYS TS I0 .iV f-oi- 

j/OteM'S?" 1 


TI02S4 2 . 
(40 VCT C 


1 ' ,< J,,,3 "LIOI 20K 


TS I0 


* v - ;> pf 1 T-f $r HBSS- - 

220 I IOWATT 
' VI 03 1 

^ 8J )W) 




[ 


-LciOZ J-CI03 T* 

TIO -r 10 

4!>OV,D.C. 410V.D.C.Ii 
TFIOJ V I04(^fe\ 
J./4A (OB2)^O 

>TSIO * 
i 240 | 




TS 1 
Q 
[]a33M 
J[ 


'... ' VI08 




COMPONENT NUMBERING SYSTEM 


10 


BASIC UNIT INCLUDING CONTROL PANEL, 
CARRIAGE AND GUN AND REMOTE 
SPEED CONTROL POT. 


2JO ^"T'jf S > 
TS 101 6\t\ 1 0^ 


20 


COMPONENTS IN AIRCOMATIC 
SPOT ACCESSORY 


O.C. WINDING / | T *l< 
OF SX 101 "T x 1 x 






PL 
335 

| -I TSI 
PL 1 101 




CIRCUIT NUMBERING SYSTEM 


10 


CIRCUITS IN PROGRAM SECTION 
OF CONTROL PANEL 


20 


. CIRCUITS IN ELECTRONIC SECTION 
OF CONTROL PANEL 


JO 


CIRCUITS IN CARRIAGE 


| 1527 SO 101 

' RII2 r L !)> T o" 07 Tllt 


40 


CIRCUITS IN GUN 


SO 


CIRCUITS IN REMOTE SPEED CONTROL 
ACCESSORY 


lj'vyA r TTl 44l ,'soioi 141 1 p 
1 4 W 

1 \-K\Jfl TS.07 -T3 




TWO DIGITS ONLY-WELD SPOT ACCESSORY 





. CIRCUITS IN AIRCOMATIC 
SPOT ACCESSORY 


| 4 2 |SOIOI ife S'V[|OJ_ 










SVMBOL 


DEFl-mrv 




REMOTE SPEED 
CONTROL ACCESSORY 

TS 1 




Ki 


BRAKE SOLENOH 






C 


CAPACITOH 






en 


CONTROL RELAY 






r 


FUSE 






c 


WELD CURRENT SOURCE 




OS 


GAS SOLENOID 




IL 


INDICATOR LIOHT 






J 


JUMPER 




L 


SMOOTHING CHOKE 




PL 


PLUG CONNECTOR 




R 


RESISTOR OR POTENTIOMETER 




W 




SW 


SWITCH 




SO 


SOCKET CONNECTOR 




SX 


SATURABLE REACTOR 






T 


TRANSFORMER 








TDK 


TIME DELAY RELAY 




TODO 


TIMES OPEN ON DROP OUT 




V 


ELECTRON TUUE 




n 

40 TSiQgCRIO 




we 


WELD CONTACTOR 




WS 


*ATER SOLENOID 




GUN 




WELDP.^^ 15 '! 


"SWWS 44 " ^102 TSOT S ^ I0 4TS,0 1: I 
(PRESSURE SWITCH) 

W "> J 'T r^" 


SWI06 %IOZ Tio? v> 



339. 



i 



PLI02 

-! OB; 

PL 102 

'""AN 
-"-_'' 

PL 10 1 




Add desired wire feed speed to this reading in 
3s-per-minute. 

Set dial to sum of steps a and b above. 

ample: If minimum is 55, and the desired wire 
;d speed is to be 185 ipm, set dial at 240. 

PRE-OPERATION CHECKS 

Turn main power switch ON at control. 
Actuate gun trigger. 

Look for leaks at hose connections and around 
3ment, and tighten or repair. 

Look for signs of overheating and burning at 
:rical points, as evidenced by brownish discolor- 
,, smoke, or odor. 

Hold gun trigger or jog button depressed for an 
val of 15, 30, or 60 seconds. Measure the amount 
re output at gun to ascertain actual wire feed speed. 

Compare actual wire feed speed with desired speed 
n dial of panel to determine whether calibration of 
potentiometer is necessary. If so, refer to the 
5! AHC-B Control manual for calibration 
'uctions. 

Turn OFF main power switch at Control. 

PRE-WELD CHECKLIST 

re operating the Feeder make sure of the following: 

All connections tight. 

Wire in drive rolls properly seated for push gun 
ation, or drive rolls removed for pull gun 
ation. 

Adjustment knob (Fig. 4) properly set. 
Lever on hub reel (Fig. 5) locked. 
Proper drag on wire reel (push gun only). 
Proper belt tension (push gun only). 

PUSH-PULL switch (Fig. 4) in proper position 
he gun being used. 

LOCAL-REMOTE switch (Fig, 4) in proper 
ion. 

Cover locked. 

Wire feed speed dial (Fig. 3) properly set. 
Water supply ON and end of drain hose visible. 
Gas supply ON. 



During operation of the Feeder, check for signs of 
leaks, and any unusual operating noises. If present, 
turn main power switch at control OFF immediately. 
After an operation, repeat the pre-operation checks. 

3.7 SHUTTING DOWN SYSTEM 

When operating during temperature above freezing, 
shut down the system by turning main power switch at 
the control OFF. Turn OFF gas and water supplies, 
Disconnect the power cord of the control. When oper- 
ating during temperatures below freezing with a water- 
cooled gun, shut down the system as follows: 

a. Turn water supply OFF. Disconnect water supply 
hose. 

b. Place main switch of power source OFF. 

c. Set selector switch in control to SCRATCH 
START. 

d. Depress gun trigger to open water solenoid. 

e. Use compressed air to blow out water lines. 

f. Turn main power switch at control OFF. 

g. Disconnect power cord of control, 
h, Turn shielding gas supply OFF. 

3.8 PRINCIPLES OF OPERATION 

This AIRCOMATIC welding system needs only two 
simple hand operations for welding after power is 
turned on: (1) setting the wire feed speed dial on the 
Feeder, and (2) pulling the gun trigger to energize the 
circuit.. The welding operation is programmed and 
electronically controlled by the Model AHC-B Control. 
Welding wire is power fed, and cooling water and gas 
are routed through the Feeder. 

Feeding of the wire i-a accomplished by a motor and 
drive rolls (Fig. 4). The motor drives the drive rolls 
through a pulley and timing belt arrangement within 
the Feeder for pushing wire through a push gun, or it 
drives a flexible shaft connected to drive rolls within 
a pull gun which pulls the wire from the reel in the 
Feeder. The drive roll housing within the Feeder in- 
cludes a worm gear on an integral bearing- mounted 
shaft to which a belt pulley is keyed. This worm drives 
two worm gears, each keyed to a bearing-mounted roll 
shaft. One shaft end holds a removable conical roll 
wire guide fitting. The other holds a grooved roll 
fitting. As the motor drives the belt pulley on the worm 
shaft, the worm drives a worm gear and roll shaft on 
either side of it, The' welding wire, gripped between 
the conical and grooved drive rolls, is thus pushed 
toward the push gun. An inlet guide bushing admits 
the wire to the drive roll housing, and after it has 
passed through the drive rolls, the wire leaves through 
an outlet guide bushing. It reaches the push gun 
through a liner within a casing coupled to the outlet 
guide bushing and connected to the gun. An adjustment 



< 




Flfurc 13. 



justment setscrew (factory-set) aligns the grooved 
roll shaft. A cam handle on the assembly, when de- 
pressed, actuates a spring- cam which moves the 
conical roll shaft away from the welding wire to 
facilitate wire- threading. 

The wire reel mounts and locks on a hub assembly 
(Fig. 13) which also provides a braking surf ace (wheel) 
for the shoe of the drag brake. The operation of the 
brake is determined by thepositionof the PUSH-PULL 
switcn. In PUSH position, the brake remains engaged 
and the brake shoe drags on the brake wheel of the hub 
to control overrun of wire from the reel. In PULL 
position, the brake is electrically released when the 
trigger switch is pulled to eliminate drag so that the 
reel is free as the wire is pulled by the gun. As soon 
as the trigger is released, the spring loaded brake re- 
engages with the brake wheel of the hub to stop wire 
pay-out. 

A brake adjustment device permits the adjustment of 
the degree of friction between the brake shoe and the 
hub brake wheel to increase or decrease the amount 

of drag sad to compensate for brake wear. 




Figur 14. F@@ctor rvie CoantttioM 
10 



sr from a source to the gun iwater-cooieo.) ana co 
current relay in the control. These services are 
'ided upon closing the trigger switch and a short 
rafter the trigger switch is released. A time delay 
y within the control provides for setting the post 
time. 

water pressure switch is factory-set to close at a 
jr pressure of 25 psi. It keeps the system in- 
ative unless inlet water pressure is at least 25 psi 



functioning of these circuits, reter to the control 
manual. 

The operating sequence of the Feeder components is 
listed in Figure 11. 



Section IV. MAINTENANCE 



GENERAL 

3 section covers inspection, preventive mainten- 
3 and service, and repairs required to keep the 
der operating efficiently. 

PREVENTIVE MAINTENANCE 

ventive maintenance consists of cleaning, tight- 
ig, and making minor repairs designed to prevent 
up time of equipment for major service and parts 
Lacement. 



CAUTION 

BEFORE MAKING REPAIRS TO THE 
FEEDER MAKE SURE POWER 
SWITCH AT CONTROLS IS OFF. 

At least every 30 days check the Feeder as follows: 

a. Look for signs of overheating of wires and 
components. 




BOLTS FOR ADJUSTING 
TIMING BELT TENSION 



TIMING 
BELT 



Figure 15. Timing Belt Adjustment 
51 




MOTOR 
PULLEY 




BELT 



BELT TENSION 



Figure 16. Adjustment Point iur Timing 



b. Check timing belt for proper tension. 

c. Check hose connections for leaks. Make sure 
cables are secure. 



At 



60 



d-d, 



as 



a Wipe away any dust, dirt and grime from Feeder. 
Use an air hose, if necessary, to blow it out. 

b Tighten all loose wire connections. Repair or 
replace any wiring with damaged insulation. 

c. Tighten all mounting hardware. 

d. Replace timing belt (Fig. 15) if worn or frayed. 
Check for proper belt tension. 

e. Check brake (Fig. 13) for proper adjustment. 

f. Lubricate gear chamber of drive roll housing 
(Fig. 4). Uiie a good grade of oil. 

e Make sure all switches are serviceable and wire 
feed speed dial and potentiometer function properly. 

4.3 REPLACING AND ADJUSTING TIMING BELT 

The motor is mounted on a spring- loaded plate held on 
a support of the carriage. This arrangement enables 



adjustment of tne timing bait tension . Ju r ^^ 
belt, it ie not accessary to disturb v., <ir>',tuj 
The belt is eased off the puheyt, axid remove v, 
the adapter is taken off the r.un-.or. Be,t a 
however, is necessary whenever a nv.aor is- 



* 

il 



in Figure 16. Make sui? the rnoior is aoprojc 
paj-allel to the motor support, or the belt :i^y 
the dinve roll pulley. 



4.4 BRAKE AD:USTMF.NT 

To adjust the brake to incre--i.se oi decrfr.se Uieair.- 
of friction between the brake shoe ana the hu.. 01 
wheel or to compensate for bral:e shoe v/ea.r, pr'J.. 
as follows: 



a. Unlock and open hinged cover. 

b. Place lock lever of hub n vertical position, 
move wire reel. 

c Turn the brake adjusting screw (.Fig. 13) 
brake shoe makes light contact with the wl 



est for proper brake adjustment by measuring 
ount of wire overrun from a full spool of wire in 
fSH mode. The overrun should be approximately 
'8- inch. 



refer to Table V to determine whether the trouble can 
be isolated to the Feeder. Then troubleshoot the Feeder 
in accordance with Table VI to repair the trouble. 
Reference to the sequence of operations (Fig. 8), 
schematic diagram (Fig. 9), and the wiring diagram 
(Fig. 10) may be desirable. 



TABLE V 
Welding System Troubleshooting 



Symptom 



Probable Cause 



Remedy 



No welding arc with 
power on and gun 
trigger depressed. 



No gas flow with 
power on and gun 
trigger depressed. 



No water flow with 
power on and gun 
trigger depressed. 



No water flow with 
power on and gun 
trigger depressed. 

No wire feed with 
power oh and gun 
trigger or wire jog 
depressed. 



a. Welding power source 
OFF. 

b. Contactor trouble. 

c. Defective cable. 

d. Malfunction in Control 

e. Malfunction in gun. 

f. Malfunction in 
Feeder. 

a. Gas source OFF. 

b. Clogged line. 

c. Malfunction in gun. 

d. Malfunction in Control. 

e. Malfunction in 
Feeder. 

a. Water source'OFF. 

b. Clogged line. 

c. Malfunction in gun. 

d. Malfunction in Control. 

e. Malfunction in 
Feeder. 

a. Malfunction in Control. 



b. Malfunction in 
Feeder. 

c. Malfunction In gun. 



a. Turn ON. 

b. Check and repair 

c. Repair or replace. 

d. See Control manual. 

e. See gun manual. 

f. See Table VI. 

a. Turn ON. 

b. Repair or replace. 

c. See gun manual. 

d. See Control manual. 

e. See Table VI. 

a. Turn ON. 

b. Repair or replace. 

c. See gun manual. 

d. See Control manual. 

e. See Table VI. 

a. See Control manual. 

b. See Table VI. 

c. See gun manual. 



53 



nu weiuuig art wiui 
power ON and gun 
trigger depressed. 



No gas flow with 
power ON and gun 
trigger depressed. 



No wire feed with 
power ON, gun 
trigger depressed, 
or gun wire jog 
depressed. 



Excessive wire 
payout in push 
operation. 



Wire slips in drive 
rolls (push operation). 



Timing belt slips off, 
drive roll pulley. 



v.iuggeu ui 
water line. 



b. Clogged water filter. 

c. Low water pressure 



d. Defective water pres- 
sure switch SW104. 

a. Clogged or pinched 
gas line. 

b. Defective gas solenoid 
GS101. 

a. Empty spool or wire 
broken near spool. 



b. Spool locked by brake. 

c. Wire jam up within 
drive roll assembly. 

d. Broken drive belt. 

e. Belt slipping. 

f. Defective motor 
wiring or motor. 

a. Insufficient drag on 
reel. 

b. Defective brake spring. 

c. Faulty brake solenoid. 

a. Improper conical roll 
adjustment. 

b. Defective spring 
within either roll 
shaft. 

a. Improper belt tension. 

b. Motor misalignment. 



a. nejja.ii ui 



b. Clean. 

c. Check pressure 
and remedy. 

d. Replace. 



a. Repair or replace. 



b. Replace. 



a. Replenish or re- 
thread wire. 



b. Adjust brake. 

c. Loosen adjustment 
knob and correct. 

d. Replace. 

e. Adjust. 

f. Repair or replace. 

a. Adjust brake. 

b. Replace brake spring. 

c. Replace. 

a. Correct with adjust- 
ment. 

b. Replace. 

a. Adjust. 

b. Adjust. 



PART 5 



AIRCOMATIC CONTROL 



MODEL AHC-B 





f '*';;! *'> ~"-'-v' v '*"- | 'W^';; 

; 

A.j.. ^L^iJL-^^c^lJ&^I 



55 




Fig. 1 Model AHC-B Control 



Section I. INTRODUCTION 



1 covers the description, installation, op- 
.intenance, and parts replacement for the 
1C Control, Model AHC-B (Fig. 1), 
3d in manual Aircomatic welding. 



cooled weld current relay. This 90-pound unit oper- 
ates with an input -of 115 VAC, 60 cps, and its power 
lines are fused at 10 amperes. Dimensions are shown 
in Fig. 2. All interconnecting cables and hoses for 
gas and water are brought into the enclosure through 
the bottom. 



IPTION 

.HC-B Control is an electronic panel used 
ind semiautomatic AIRCOMATIC welding 
to program the welding operation. It can 
rated when connected within a system con- 
MRCOMATIC welding gun, Model AHF-E 
Vire Feeder, and a welding power source, 
sm needs only two hand operations for weld- 
s power is turned on: a pre-setting of wire 
Dn a dial of the Wire Feeder, and a pull of 
ger. The Control automatically programs 
m by timing and sequencing the gas flow, 
wire feeding, and weld current. At the 
'eld, it provides dynamic motor braking, 
all-type guns, an electric brake for wire- 



1 is a compact steel enclosure with a hinged 



an electro-mechanical weld programming 
electronic speed control section, a water- 



1. 2. 1 CONTROL COMPONENTS 

A current relay applies welding current from the 
power source. It contains two welding cable lugs and 
a water connection gland. 

Three fuses protect the Control circuitry: two power 
line fuses and a l/4amp fuse fora full-wave rectifier 
in the speed control section. 

The weld programming section receives the input 
power, energizes the speed control section, and uses 
a time -delay relay and a number of control relays. 
These sequence the integrated welding steps such as 
feeding weld current, wire, and gas and water flow 
once the gun trigger is pulled. 

The speed control section electronically regulates the 
motor to produce the desired wire feed rate set man- 
ually on the wire feed speed dial of the feeder. It 



57 




27 YA 



Vt 



10 /4 -| 

NOTE; ALL DIMENSIONS ARE APPROX. 



Fig. 2 Dimensions 



contains a printed circuit board with a rectifier, am- 
plifiers, voltage regulators, resistors, capacitors, 
and a saturable reactor. These comprise a full-wave 
rectifier, a motor control circuit, and a motor-run 
circuit. 

1.2.2 OPERATING CONTROLS AND INDICATORS 

The controls and indicators used for operation of the 
Control are a main power switch, a power-ON indi- 
cator lamp, a wire feed selector switch, a wire feed 
calibration rheostat, and a rough-service lamp re- 
sistor. 



1.3 SUPPORTING EQUIPMENT 

Supporting equipment includes other basic components 
which must be used in a system with the Control such 
as an AIRCOMATIC push or pull welding gun arid a 
Model AHF-E Push- Pull Wire Feeder. 



Section ||. INSTALLATION 



This section covers installation of the Control and 
interconnection with all basic components needed for 
the operation of an AIRCOMATIC welding system. 

2.1 UNPACKING, INSPECTION AND ASSEMBLY 

Unpack the Control carefully so as not to damage any 
parts or mar any finished surfaces. Check the en- 
closure, both inside and out, for any signs of damage. 
Unwrap the tubes and capacitois, and install these on 
the Control chassis (Fig. 3). Report any damage im- 
mediately to your nearest AIRCO representative. 



7.2 LOCATION AND MOUNTING 



Choose a location for the Control that will have free 
and easy access. Allow for complete opening of the 
hinged door. Make certain there will be sufficient 
space for connecting cables and hoses at the base. 



Secure the Control to a wood panel. Place it so that 
the Power-ON lamp atop the Control will be at aver- 
age eye-line height. 



RECTIFIER V102 



AMPLIFIER. VI05 




THYRATRON . V101 



Fig. 3 Tube and Fuse Location 



INECTINO CONTROL 



ing sure that the main power switch (Fig. 4) 
onnect Control in accordance with intercon- 
agram (Fig. 5) as follows: 

: the power cord into a 115 VAC supply. 

it the two groups of leads of the multi-con- 
)le (part of the hose and cable kit described 
;der manual) through the cord grip in the 
the Control. Connect the group containing 
r number of leads to the proper terminals 
al strip TS101. (The numbers on the leads 
d to the points on the terminal strip to which 
h. ) Connect the other group of leads to the 
rminals on terminal strip TS104. Secure 

Tip, 

secondary weld contactor is used, bring the 
n the contactor coil through the rear cord 



grip of tha Control, 
and 106 on TS102. 



Attach the leads to points 157 



d. If a water-cooled gun is to be used, attacha 5/16 
ID hose from the drain to the right hose connector. 

e. If a water-cooled gun is to be used, attach the 
water hose (part of the hose and cable kit described 
in the feeder manual) from the feeder to the left hose 
connector. 

f. Connect a welding cable from the left hose con- 
nector to the workpiece. See Table I for the correct 
size. 



g. Connect a welding cable from the right hose con- 
nector to the negative (-) terminal of the power source. 
See Table I for the correct size. 



TABLE I. Cable Size Selector Guide 





Feet 


ips 


50 


75 


100 


125 


150 175 200 225 250 300 350 400 


00 


2 


2 


2 


2 


1 


1/0 


I/O 


2/0 


2/0 


3/0 


4/0 


4/0 


50 


2 


2 


1 


1/0 


2/0 


3/0 


3/0 


4/0 










00 


2 


1 


1/0 


2/0 


3/0 


4/0 


4/0 












50 


2 


1/0 


2/0' 


3/0 


4/0 
















00 


1 


2/0 


3/0 


4/0 


















50 


1/0 


2/0 


4/0 




















00 


1/0 


3/0 


4/0 




















50 


2/0 


3/0 






















00 


2/0 


4/0 























59 



POWER ON 
INDICATOR 



SPEED CONTROL 
SECTION 



CALIBRATION 
REOSTAT R1U 




WELD CURRENT 
RELAY CR101 



WIRE FEED SELECTOR 
SWITCH. SW102 



MAIN POWER 
SWITCH. SWI01 



WELD PROGRAM 
SECTION 



Fig. 4 Model AHC-B Control (Inside View) 



2.4 RUN-IN OR SCRATCH-START MODiS 

Selection of the starting mode, RUN-IN or SCRATCH- 
START, depends upon the type of wire and welding 
power source to be used. Refer to Table II. 



TABLE II. Selection of Wire- Feed Starting Method 



Wire Type 


Power Source Type 


Drooping 
Character- 
istic 


CAV or RAV 


Aluminum, Magnesium, 
Copper, and Copper 
Base Alloys 


Scratch- Start 


Run-in Start 
or 
Scratch Start 


Others 


Run-in Start 
Scratch Start 


Run-in Start 
or 
Scratch Start 



2.5 SITTING POST-WELD GAS AND WATER FLOW 

a. Adjust the timer on the time-delay relay 
(TDR101). 

NOTE: The timer is factory-set 
for 5 seconds of post-weld gas and 
water flow. The adjusting screw has 
a calibrated range of to 99. 

b. Turn main power switch (Fig. 4) OFF. 

c. Open Control door. Check reading of adjusting 
screw. 

d. Turn adjusting screw counterclockwise to IN- 
CREASE time flow interval, and clockwise to de- 
crease. 



DETAIL OF MULTI-CONDUCTOR 
CABLE CONNECTIONS INSIDE 
OF CONTROL 



ON-OFF 
TOGGLE 
SWITCH 



oooooooooopooo , 

RSRSj i 

rn fit tv (V ty | 
I 



OF OPER 
I TOGGLE 

:H 

'CH START' 
!N START " 



WATER FROM CURRENT RELAY TO DRAIN 



lib V AC SUPPLY 



SECONDARY 
WELD CONTACTOR 



WATER- OUT TO 
CURRENT RELAY 



MULTI- CONDUCTOR CABLE 
TO WIRE FEEDER 



TO COIL OF WELD CONTACTOR 



L.LDING CABLE TO 
IRE FEEDER 



WELDING CABLE TO 
CURRENT RELAY 




JUMPER J2 

TO COIL OF 

WELDING 

CONTACTOR 



CONTACTOR CONTROL LEADS 



IF WELDING POWER SOURCE 
CONTAINS CONTACTOR - 
CONNECT CONTACTOR CONTROL 
LEADS TO RECEPTACLE ON 
POWER SOURCE. 
Z CONNECT LEAD FROM 
POSITIVE TERMINAL 
DIRECTLY TO WIRE FEEDER 



WORK ELECTRODE 



Comply with all ventilation, fire, and other safety re- 
quirements (or welding as established for industrial 
implications. Reference as applicable: 

a. "Safety in Electric and Gas Welding and Cutting 
Operations", American Standards Association: Bulle- 
tin Z49.1, 1958. 

b. "Recommended Safe Practices for Inert-Gas 
Metal -Arc Welding 1 " American Welding Society; 
Bulletin A6. 1, 1958. 



Because of infrared radiation emitted by the high- 
intensity are in Aircomatlc welding methods, flash 
goggles (medium-shade 1306 2101) are recommended 
ill addition to helmet for the operator and near-by 
personnel. The welding wire (electrode) and all metal 
parts in contact with it are electrically energized while 
welding, requiring periodic inspection of cables for 
oroken insulation, water leakage, and other electrical 
hazards. 

CAUTION 

WHENEVERSTEPS ARETAKENTO 
REMOVE AND REPAIR ELECTRI- 
CAL HAZARDS, PLACE ALL POW- 
ER CONTROLS OFF AND DISCON- 
NECT ALL ELECTRICAL CABLING 
FROM POWER SOURCES. 

1.2 GENERAL 

The Control can only be operated when connected 
within a welding system. This section covers only 
pre-weld requirements, and operation sequence, cali- 
bration, and checks during and after operation. 

3.3 PRE-WELD REQUIREMENTS 



Before operating the Control in a welding system: 

a. Turn main power switch (SW101) (Fig. 4) OFF. 

b. Make sure all connections of hoses and cables 
are tight. 

c. Set wire feed selector switch (SW102) in 
SCRATCH-START or RUN-IN position. 

d. Check for proper adjustment of time-delay relay. 

e. Close control door. 

f. Turn main power switch (SW101) ON. Allow at 
least a 30-second warm-up interval for equipment 
before welding. 

3.4 OPERATION 

Operation of the Control In an energized welding sys- 
tem is remotely controlled by the trigger or wire jog 
on the gun. 



During operation of the Control to insure proper oper- 
ation: 

a. Carefully open Control door. Make sure lamp 
glows when power switch is ON. 

NOTC: This !amp goes out when 
gun trigger or wire jog is depressed. 

b. Check for leaky hoses. Shut down system before 
making any repairs. 

After operation of the Control, check for leaks and 
look for signs of overheating at electrical points as 
evidenced by brownish discoloration, smoke or odor. 
Recheck interconnections, or troubleshoot as neces- 
sary. 

3.6 OPERATING SEQUENCE 

During a system operation, the Control performs four 
sequences (Figs. 6, 7,and 8): 

a. Wire jog sequence for advancing w'.re without 
gas and water flow. 

b. Run-in Start sequence for feeding wire with gas 
and water supplies. 

c. Scratch-Start sequence for supplying gas and 
water, but feeding wire only after wire electrode is 
scratched against workpiece. 

d. End of weld sequence. 

3.7 SHUTTING DOWN CONTROL 

To shut down Control, turn power switch(Fig, 4) OFF. 

MOTS: At freezing temperatures, 
purge water lines before turning off 
the Control. 



3.8 PRINCIPLES OF OPERATION 

3. 8. 1 PROGRAM SECTION 



After the gun trigger is pulled, the program section 
receives the input power, energizes the speed control 
section, and uses a time-delay relay and control relays 
to sequence the weld current, wire, gas, and water 
flow. 

When the input voltage is impressed across the sec- 
ondary of transformer T101S and the gun trigger is 
pulled, control relay CR103 is energized. It oper- 
ates the time -delay relay TDR101 which in turn ener- 
gizes the gas and water solenoids. The time-delay 
relay also governs the time interval during which gas 
and water flow after the gun trigger is released. This 



62 





9 1 


) 







T 




> ~ 1 


. . 




<r " ' 


r ~ - 




S 


oc 




] i- 


p 

P 




in 


) 


- 



i 




i<"o idioioioiolo'p'oii 
trilLJ-J.-1-lIlLlJ. 



TSI06 



(RECTIFIER) 



,2H 



100 



200 




COMPONENT NUMBERING SYSTEM 



BASIC UNIT INCLUDING CONTROL PANEL. 
CARRIAGE AND GUN AND REMOTE 
5PEELCONTR_Ok_POT. 



COMPONENTS IN AIRCOMATIC 
SPOT ACCESSORY 





CIRCUIT NUMBERING SYSTEM 


100 


CIRCUITS IN PROGRAM SECTION 
OF CONTROL PANEL 


200 


CIRCUITS IN ELECTRONIC SECTION 
OF CONTROL PANEL 


300 


CIRCUITS IN CARRIAGE 


400 


CIRCUITS IN GUN 


100 


CIRCUITS IN REMOTE SPEED CONTROL 
ACCESSORY 




TWO DIGITS ONLY-WELD SPOT ACCESSORY 


eoo 


CIRCUITS IN AIRCOMATIC 
SPOT ACCESSORY 



SYMBOL 


DEFIMTION 


B3 


BRAKE SOLENOID 


C 


CAPACITOR 


CK 


CONTROL RELAY 


F 


FUSE 


G 


WELD CURRENT SOURCE 


CS, 


GAS SOLENOID 


IL 


INDICATOR LIGHT 


J 


JUMPER 


L 


SMOOTHING CHOKE 


PL 


PLUG CONNECTOR 


R 


RESBTOR OR POTENTIOMETER 


SW 


SWITCH 


SO 


SOCKET CONNECTOR 


sx 


SATURABLE REACTOR 


T 


TRANSFORMER 


TDR 


TIME DELAY RELAY 


TODO 


TIMES OPEN ON DROP OUT 


TS 


TERMINAL STRIP 


V 


ELECTRON TUUE 


we 


WELD CONTACTOR 


WS 


WATER SOLENOID 




REMOTE SPEED 
CONTROL, ACCESSORY 



GUN 



TSI02 C 




SWIGS 4 *' 30,02 TSI07 SWI04 T 

(PRESSURE swi 

WIRE JOC, p,| 02 

.^- tl vv 3SI 



SO|( 



SWIO 



TSI07 



Wire Jog Sequence 



Throw SW101 (wait 30 seconds) 

Push SW106 (jog button) 

i 

CR104 P. U. 

I 



:RIOS p. u. 

motor runs) 
[wire feeds) 



BS101 P.O.* 
(brake releases) 



Release SW106 



:R105 D.O. 
motor stops) 
Ire feed stops) 



BS101 D. O. * 
(brake applied) 



Wire Feed Selector in "Run-in Start" Position 



SW102 in run-in start position 
SW104 (pressure switch closed) 
Throw SW101 (wait 30 seconds) 

Pull SW105 (weld trigger) 
CR103 P. U. 



rDRlOl P. U. 

01 P. U. WS101 P. U. 
?as and water flow) 



WC. P. U. 

I 
I 
I 



CR105 P. U. 

(motor runs) 

(wire feeds) 

I 



BS101 P. U. * 
(brake released) 



Wire touches work 
arc established 



Wire Feed Selector In "Scratch Start" Position 



SWI02 in scratch start position 
SW104 (pressure switch) closed 
Throw SW101 (wait 30 seconds) 

Pull SW105 (weld trigger) 
CR103 P. U. 



TDR101 P. U. 
I 

101 P. U. WS101 P.U. 
gas and water flow) 



WC. - P.U. 



wlr 



Scratch wire on work 
CR101 P.U. 

arc established 
CR102 P.U. 



End of Weld Sequence 



J 

CR105 P.U. 
(motor runs) 
(wire feeds) 



BS101 P. U. * 
(brake released) 



Release SWIO^ (weld trigger) 

CR103 D.O. 
I 



'DR101 D.O. 
starts timing) 



OR101 Times Out 

I 

J I 

.01 D. 0. SW101 D.O. 
i and water stop flowing) 

ly if SW107 in PULL (closed) position. 



CR105 D.O. 
(motor stops) 
(dynamic braking) 
(wire stops feeding) 



BS101 D. 0. * 
(brake applied) 



Fig. 8 Sequence Chart 



67 



reel for pull guns. This section is also provided with 
an input receptacle for an AIRCOMATIC spot acces- 
sory used for spot-welding. The power input of the 
section passes through the Run trigger and a water 
pressure switch (S/W104) factory-set at 25 psi, so that 
even though the gin trigger is depressed, the Control 
remains inoperative if there is insufficient cooling 
water in the system. 

3.8.2 SPEED CONTROL SECTION 

The speed control section electronically regulates 
the speed of the wire feed motor to produce'the re- 
quired wire feed speed. It contains a printed circuit 
boardwith a rectifier, amplifiers, voltage regulators, 
resistors, capacitors, and a saturable reactor. These 
comprise a full-wave rectifier, a motor control cir- 
cuit, and a motor-run circuit. The rectifier converts 
input AC to filtered, regulated DC for the control cir- 
cuit. The control circuit uses a dual triode to am- 
plify the electrical equivalent of the motor speed from 
a tachometer-generator on the wire feed motor. Onto 



wire feed motor. Thus, the motor speeds up or slows 
down, depending on the relation of its speed to that set 
on the dial. When the gun trigger switch is energized, 
the motor-run circuit is in a relay condition. This 
places the motor armature in series with the motor 
field. Release of the trigger sets up a relay condition 
which places the armature in parallel with the field, 
and in series with a 50-watt lamp so that dynamic 
braking occurs, and the lamp glows. Hence, the lamp, 
when lit, indicates a stand-by condition of the motor 
(no wire feed). This is the same condition that exists 
when only the main power switch (SW1 01) is turned ON. 

3. 8. 3 ELECTRIC BRAKE FOR WIRE REEL 



In pull-type gun systems, the Control electrically re- 
leases a brake in the Wire Feeder to prevent drag on 
the wire reel. When the gun trigger or jog switch is 
energized, control relay CR103 or 104 in the Control 
(Fig. 9) energizes brake solenoid (BSlOl)inthe feeder 
to release the brake on the wire reel hub. 



INDUCTOR. L10I 



CAPACITOR C104 



RESISTOR RI08 



RESISTOR. RI04 



RESISTOR. RIO 



CAPACITOR. C.10I 



RESISTOR. R107 



SATURABLE 
REACTOR. 5X101 



TRANSFORMER T102 




RESISTOR. R109 

RESISTOR. RIO) 



TIME DELAY 
RELAY TDRtOl 



CONTROL 
RELAY. CRIOS 



CONTROL 
RELAY CRI04 



CONTROL 
RELAY CR103 



CONTROL 
RtLAY. CR104 



Fig. 9 Control Components 



68 



NERAL 

:tion covers inspection, preventive mainte- 
.nd service and repairs required to keep the 
at minimum standards for efficient operation. 

EVENTIVE MAINTENANCE 



VERY 30 DAYS 

every 30 days, check the Control: 

rn main power switch (Fig. 4) OFF. 

en Control door. Look for signs of overheat- 

irning of wiring or components. 

ke sure tube and other plug-in parts are 

sck that all cable and hose assemblies are 

ok for signs of physical damage inside or out- 
Control. 

VERY 60 DAYS 

every 60 days, perform the following: 

rn main power switch (Fig. 4) OFF. Open 

door. 

pe away dust, dirt, and grime. Use an air 

necessary, to blow it out of Unit. 

;hten all loose wire connections. Repair or 

any wiring with damaged insulation. 

;hten all mounting hardware. 

kLIBRATING PROCEDURE 

ation rheostat (Fig. 4) is provided in the Con- 
calibrating the front-panel dial of the wire feed 



speed potentiometer on the feeder. Use this rheostat 
to calibrate the dial as follows: 

a. Choose an interval of time (15, 30, or 60 seconds) 
for testing a wire feed operation. (The greater the 
interval, the more accurate the test. ) 

b. Set dial on feeder for desired rate of wire feed. 

c. Operate system (jog or trigger on gun depressed) 
to feed wire only for interval of time selected. 

d. Measure output of wire fed from gun. Convert 
this to inches-per-minute. 

e. Check this output in inches-per-'minute with op- 
timum suggested by appropriate chart of Figure 10 
for dial setting used in test. 

f. If output is less than optimum suggested, turn 
rheostat clockwise slightly. Repeat steps a through 
. If it is more, turn rheostat counterclockwise and 
"repeat operation. 

NOTE: Calibration is complete 
when the actual wire output speed 
matches the optimum suggested by 
the charts. 

4.4 TROUBLESHOOTING 

Whenever a malfunction occurs in the welding system, 
refer to Table HI to determine whether the trouble 
can be isolated to the Control. Troubleshoot the Con- 
trol in accordance with Table IV. 

NOTls Before troubleshooting 
make sure system has adequate in- 
let water pressure. 




I --, g o 



....... , , I 

i ! 1... i , i. i - 

200 400 600 800 1000 

DIAL CALIBRATION - - - PULL C.UN 
PUSH GUN 



Fig. 10 Calibration Charts 



TABLE in. Troubleshooting System 



Symptom 


Probable Cause 


Remedy 


No welding arc with power ON and gun 
trigger depressed 


a. Welding power source OFF 
b. Contactor trouble 
c. Defective cable 
d. Malfunction in Control 


a. Turn ON. 
b. Check and repair, 
c. Repair or replace, 
d. See Table IV. 




e. Malfunction in gun 
f. Malfunction in Wire Feeder 


e. See gun manual, 
f. See Wire Feeder 






manual. 


No gas flow with power ON and gun 
trigger depressed 


a. Gas source OFF 
b. Clogged line 
c. Malfunction in gun 
d. Malfunction in Control 


a. Turn ON. 
b. Repair or replace, 
c. See gun manual, 
d. See Table IV. 




e. Malfunction in Wire Feeder 


e. See Wire Feeder 






manual. 


No water flow with power ON and gun 
trigger depressed 


a. Water source OFF 
b. Clogged line 
c. Malfunction in gun 
d. Malfunction in Control 


a. Turn ON. 
b. Repair or replace, 
c. See gun manual, 
d. See Table IV. 




e. Malfunction in Wire Feeder 


e. See Wire Feeder 






manual. 


No wire feed with power ON and gun 
trigger or jog depressed 


a. Malfunction in Control 
b. Malfunction in Wire 


a. See Table IV. 
b. See Wire Feeder 
manual. 




c. Malfunction in gun 


c. See gun manual. 



4.5 CIRCUIT REPAIRS 

The circuits within the Control are designed for long- 
life and trouble-free operation. The speed control 
section consists of a printed circuit board, a replace- 



able unit. Hence, troubleshooting and repairs by the 
user should be limited to replacement of plug- in parts. 
Components such as transformers, resistors, capaci- 
tors, etc. should be checked and replaced by skilled 
personnel only. Use Table IV as a guide. 



70 



TABLE IV. Troubleshooting Control (Figs. 7 and 8) 



Symptom 


Probable Cause 


Remedy 


er-On Lamp atop Control does not 


a. No primary power 


a. Connect power cord 


/ with main power switch ON 




to primary source. 




b. Defective fuse F101 or F102 


b. Replace. 




c. Defective lamp 


c. Replace. 




d. Defective switch 


d. Replace. 


velding arc with power on and gun 


a. Defective control relay CR103 


a. Replace. 


ger depressed 


b. Defective control relay CR101 


b. Replace. 




c. Defective wiring associated 


c. Check continuity 




with steps a, b, or c, above 


and repair or re- 






place. 




d. Defective transformer T 101 


d. Replace. 


vire feed with power on and gun 


a. Defective control relay CR104 


a. Replace. 


?er or jog depressed 


b. Defective control relay CR105 


b. Replace. 




c. Defective thyratron VI 01 


c. Replace 




d. Defective amplifier VI 05 


d. Replace. 




e. Defective regulator VI 03, VI 04 


e. Replace. 




f. Defective rectifier V102 


f. Replace. 




g. Defective transformer T102 


g. Replace. 




h. Defective reactor SX101 


h. Replace. 




i. Defective transformer T101 


i. Replace. 


vire feed with power on, wire 


a. Defective control relay CR103 


a. Replace. 


ctor switch SW102 in RUN-IN 


b. Check steps b through i above 


b. Replace neces- 


tion, gun trigger depressed 


for wire jog condition 


sary parts. 


vire feed with power on, wire 


a. Defective control relay CR103 


a. Replace. 


ctor switch SW102 in SCRATCH- 


b. Defective control relay CR102 


b. Replace 


RT position, gun trigger de- 


c. Check steps b through i above 


c. Replace neces- 


3sed, and wire electrode scratched 


for wire jog condition 


sary parts. 


/ork 


d. Defective control relay CR101 


d. Replace. 


jas or water flows with power on, 


a. Defective control relay CR103 


a. Replace. 


gun trigger depressed 


b. Defective time-delay relay 


b. Replace. 




TDR101 






c. Defective wiring to gas or 


c. Repair or re- 




water solenoid in Wire Feeder 


place. 



TABLE V. Functions of Electronic Components (Figs. 7 & 9) 



Components 


Symbol 


Function 


Capacitors 


C101 


(. 001 mf, 600 WVDC) thyratron grid capacitor prevents thyratron 
from firing due to undesirable voltages in thyratron grid circuit. 




C102 
C103 


(10 mf, 450 WVDC) filter capacitor for output of full-wave rectifier 
VI 02. 




C104 


(0. 5 mf, 600 WVDC) used with resistors R108 and R109 to improve 
response of motor to sudden changes in load or wire feed speed. 


Fuses 


F101 
F102 


(10-amp) in 115 V, 60 cps input lines to protect Control circuits 
against overloading. 




F103 


(1/4-amp) protects full-wave rectifier V102. 


Indicator 


IL 


Glows when main power switch SW101 is ON. 


Inductor 


LI 01 


(8 henrys) filters AC ripple from rectifier V102 output. 


Relays 


CR101 


(Single-pole, double-throw) current relay, picks up at approximately 
100 amperes when weld power source current flows in welding 
circuit; energizes CR102 for "scratch-start". 




CR102 


(Double-pole, double-throw) picks up at about 11 volts to energize 
CR105 during "scratch-start" operation. 




CR103 


(Four-pole, double-throw) weld relay, energized when gun trigger 
is depressed; energizes TDR101 for gas and water flow, WC relay 
for weld current, and CR105 for operation of wire feed motor. 




CR104 


(Four-pole, double-throw) picks up when wire jog on gun is de- 
pressed to energize CR105 to enable wire feed without gas and 
water flow. 




CR105 


(Four-pole, double-throw) picks up when gun trigger or wire jog is 
depressed to operate wire feed motor by placing motor armature in 
series with field; when trigger or jog is released, places armature 
in parallel with field for dynamic braking. 




TDR101 


(Single-pole, double-throw) pneumatic off-relay; energizes gas and 
water solenoids in Wire Feeder to apply shielding gas and cooling 
water at gun; also times and limits post-weld flow of gas and 
water. 


Resistors 


R101 


(4000 ohms, 5 watts, fixed) In series with AC winding of saturable 
reactor SX101 to supply a phase-shifted voltage to thyratron V101. 
Amount of phase-shift determines wire feed motor speed. 




R102 


(220,000 ohms, 1 watt, fixed) Limits current to grid of thyratron 
VI 01. 




R103 


(50 watts, 125 volt, lamp bulb) Used in dynamic braking at end of 
weld cycle when gun trigger is released. 



72 



Jomponents 



Symbol 



Function 



sistors (cont) 



R104 

R105 

R106 
R107 

R108 
R109 



turable 
actor 

itches 



R110 
R114 
SX101 
SW101 

SW102 



ansformers 



ibes 



T101 
T102 

V101 
V102 



V103 
V104 

V105 



(20, 000 ohms, 10 watts, fixed) Used with voltage regulators V103 and 
VI 04 to regulate voltage to amplifier V105 and wire feed speed poten- 
tiometer Rill in Wire Feeder. 

(330, 000 ohms, 1 watt, fixed) Voltage dropping resistor in plate cir- 
cuit of V105A which limits voltage to grid of V105B. 

(1 megohm, 1 watt, fixed) Prevents current flow to grid of V105B. 
(220,000 ohms, 1 watt, fixed) Prevents current flow to grid of V105A. 

(50,000 ohms, 10 watts, fixed) Voltage divider across output of 
tachometer-generator on motor shaft. Voltage across R108 with that 
of capacitor C104 improves response of motor to sudden changes in 
load. Voltage across R109 is added to that of wire feed speed poten- 
tiometer Rill in Wire Feeder (hand-set for desired speed), and 
amplified by VI 05. The result is then applied through saturable re- 
actor SX101 to thyratron VI 01 to alter motor speed. 

(30, 000 ohms, 10 watts, fixed) Supplies necessary reference voltage 
to wire feed speed potentiometer in Wire Feeder. 

(20, 000 ohms, 4 watts, variable) Used for fine calibration of wire 
feed speed potentiometer Rill in Wire Feeder. 

Part of phase- shift circuit for control of wire feed motor. 



(Double-pole, double-throw) Control circuit switch connects Control 
components to 115 VAC supply. 

In SCRATCH START position, only gas and water are supplied to gun 
when gun trigger is depressed, and wire must be scratched on work- 
piece to supply weld current and wire. In RUN-IN position, wire, 
weld current, gas, and water are supplied at gun when gun trigger is 
depressed. 

Supplies 25. 2 VAC to gun controls and coils of CR103 and CR104. 

Power transformer, supplies the following AC voltages: 180 V to 
thyratron V101 plate; 50 V to phase-shift windings in motor-run 
circuit; 2. 6 V to thyratron filament; 640 V to rectifier V102; 5 V to 
rectifier filament; and 6. 3 V to amplifier V105 heaters. 

Thyratron C3J controls speed of wire feed motor by regulating 
voltage in motor- run circuit. 

5Y3 full-wave rectifier rectifies input AC for use by motor control 
circuit. 

OB3 voltage regulators keep output voltage of thyratron V101 con- 
stant for motor control circuit. 

12AT7 dualtriode combines output voltage of tachometer-generator on 
Wire Feeder motor (voltage equivalent of motor speed) with voltage 
equivalent of desired wire feed speed (hand-set on wire feed speed 
potentiometer) for use by motor control circuit. 



73 



SCOPE 



for 

WATER CIRCULATING UNIT 
Section 1. INTRODUCTION 



manual provides instructions for installation, operation, and maintenance, for 

,IRCO < heavy -duty Water Circulating Unit. This Unit recirculates water or other fluid to cool welding equipment. 



DESCRIPTION 

Jnit consists of a sturdy rectangular steel tank and cover on top of which is mounted a heavy-duty motor coupled to a 
/ pump. A toggle switch on the motor starts and stops the 1 15/230 volt ac motor. The Unit can supply sufficient 
nt up to a 40-foot head. The approximate dimensions (in inches) for the Unit are shown in Figure 1. 




ALL DIMENSIONS ARE APPROX. 



DIM 




IOGAL 
TANK 


A 




lOlfc 


B 




24" 


C 




h>" 



Figure /. Dimensions (40 Gall Unit Shown) 

iischarge line of the Unit has a safety relief valve which by-passes the equipment and allows coolant to go directly to the 
when discharge back pressure exceeds the relief-valve pressure setting. 

ank is supplied with four hold-down clamps intended to keep it from shifting in service. The interior of the tank is 
d with a rust-resisting paint. 

ironze water pump is a rotary -gear type with a stainless steel shaft. Carbon shaft bearings are lubricated by the liquid 
pumped. A positive mechanical-type lip seal on the pump-coupling shaft needs no mechanical adjustment. 



Section II. INSTALLATION 



2.1 MOUNTING AND CONNECTIONS 

a. If the Water Circulating Unit is used in a moving vehicle, 
use the four hold-down clamps supplied as shown in Figure 2. 

b. Attach the coolant inlet hose of the welding device to 
the connection on the water block marked WATER IN. 

c. Attach the coolant outlet hose of the welding device to 
the connection on the water block, marked WATER OUT. 

d. The motor comes equipped with wire and plug for 1 IB- 
volt ac operation. For 230-volt operation, change the wire and 
plug and refer to Figure 3 to convert the motor. 

e. Plug the circulator motor line cord into a suitable power 
outlet and attach the ground wire to a suitable ground connection. 



HOLD- DOWN 
CLAMP 




Figure 2. Circulator Mounting 



The motor must run continuously. Never con- 
nect the Water Circulating Unit so its motor 
starts and stops with each operation of a weld- 
ing contactor. The cooling efficiency of the 
unit will be hampered and the starting wind- 
ing in the motor may burn out. 

2.2 LUBRICANT 

The life of the Water Circulating Unit pump increases if a lubri- 
cant is added to the water in the tank. A quart of Socony- 
Vacuum, Solval No. 1535, stock no. 2390 0404 is supplied with 
each Unit. A quart should be added to every 1 gallons of water. 

Where freezing conditions may be encountered, permanent type 
anti-freeze must be added. The proper quantity of anti-freeze to 
be added will depend on the lowest expected temperature in the 
area and quantity of water. Anti-freeze may be used as a sub- 
stitute for the lubricant. 



L2 1 L2 


(? 4 


4 


' fl\ 


,x_J0 


@ 3 


t ^-^ 


2 










LI 


L) 


230 VOLTS 


115 VOLTS 



Figure 3. Mo tor Jumper L oca tion 



Section III. OPERATION 



HELIWELD and Al RCOMATIC equipment may be operated at their full rated current for at least three hours continu- 
ously. This duty cycle is based on a 40F (22.3C) coolant temperature rise above an 80F (26.7C) ambient when used 
with arc-welding devices. 



Coolant temperature should never exceed 120F (49C). 



A maximum relief valve setting of 40 psi must be maintained. 
Higher pressure may overload the motor or cause damage to the 
hoses. At least a 30 psi relief valve setting must be maintained 
to assure an adequate coolant supply to equipment. 



Section IV. MAINTENANCE 



ERAL 



circulating tank should be cleaned periodically and replenished with fresh water and lubricant. Oil the motor shaft 
everal times a year with a good grade of light motor oil. The pump bearings require no lubrication other than that 
3y the coolant. 



CAUTION 



Unplug motor from power before making any motor repairs or 
replacements. 



3ON BEARING REPLACEMENT 



It is generally advisable not to replace carbon bearings in the field. 
This operation requires tools and experience. If done improperly 
it can ruin the pump and/or burn out the motor. Usually, when 
carbon bearings are worn out, body and cover casting are equally 
worn, and replacement of the whole assembly is indicated. How- 
ever, if field replacement becomes necessary, the following pro- 
cedure is applicable. 

e old bearing, heat pump body (or cover) to about 300 to 400 degrees F. Since thermal expansion rate of mstal is 
ner than that of carbon, carbon bearings will drop out readily. 



Do not heat casting over 400 degrees F to prevent warping it. 



new bearing, make up a proper arbor that slips with 
,005-inch clearance into bearing bore, with a shoulder 
irger than the outside diameter of bearing (Figure 4.) 

NOTE 

Carbon bearings are made several thousandths 
oversize to housing bore to assure press fit. 

id press or bench vise (rather than a hamrper) for press- 
ng in. Make sure face of casting is at right angles to 
-it of iarbor. Press bearing in flush with casting face; 
flusH if neces~3ry. Use reamer of finishep bore size 
)2 inj dia) to ream bearing to proper Inside diameter, 
approximately 1/64-inch stock (in diameter) to be re- 



0.005 
CLEARANCE 




'e 4. Bearing Installation 



APPENDIX A 
REFERENCES 



1. FIRE PROTECTION 
TM 5-4200-200-10 

2. PAINTING 
TM 9-213 

3. MAINTENANCE 
TM 38-750 

1*. SHIPMENT AND STORAGE 
TB 7MD-93-2 

TM 7^0-90-1 
TM 38-230 



Hand Portable Fire Extinguishers 
For Army Users 



Painting Instructions for Field 
Use 



Army Equipment Record Procedures 



Preservation of USAMEC Mechanical 
Equipment for Shipment and Storage 

Administrative Storage of Equipment 

Preservation, Packaging, and Packing 
of Military Supplies and Equipment 



A-l 



APPENDIX B 

BASIC ISSUE ITEMS LIST 
Section I . INTRODUCTION 
B-I. Scope. 

This appendix lists items which accompany the welding set or are 
required for installation, operation, or operator's maintenance. 

B-2. General. 

This Basic Issue I terns List is divided into the following sections: 

a. Basic Issue I terns - Sectio, 
accompany the welding set and are 
installation, operation, or mai ntencmv_t. 

b. Maintenance and Operating Supplies - Sei 

of maintenance and operating supplies required ror initial operation. 

B-3. Explanation of Columns. 

The following provides an explanation of columns in the tabular 
list of Basic Issue Items, Section II. 

a. Source, Maintenance, and Recoverabi 1 i ty Codes (SMR) : 

(l) Source code, indicates the selection status and source 
for the listed item. Source codes are: 

Code Explanation 

P Repair parts which are stocked in or supplied from the 

GSA/DSA, or Army supply system and authorized for use 
at indicated maintenance categories. 

P2 Repair parts which are procured and stocked for insurance 

purposes because the combat or military essentiality of 
the end item dictates that a minimum quantity be available 
in the supply system. 

M Repair parts which are not procured or stocked, but are 

to be manufactured in indicated maintenance levels. 



B-l 




Code Explanation 

A Assemblies which are not procured or stocked as such, 
but are made up of two or more units. Such componeht 
units carry individual stock numbers and descriptions, 
are procured and stocked separately and can be assembled 
to form the required assembly at indicated maintenance 
categories , 

X Parts and assemblies which are not procured or stocked 
and the mortality of which normally is below that of 
the applicable end item or component. The failure of 
such part or assembly should result in retirement of 
the end item from the supply system. 

XI Repair parts which are not procured or stocked. The 
requirement of such items will be filled by use of the 
next higher assembly or component. 

X2 Repair parts which are not stocked. The indicated 

maintenance category requiring such repair parts will 
attempt to obtain them through canni bal i zat ion. Wherfe 
such repair parts are not obtainable through canni- 
balization, requirements will be requisitioned, with 
accompanying justification, through normal supply 
channel s. 

C Repair parts authorized for local procurement. Where 
such repair parts are not obtainable from local pro- 
curement, requirements will be requisitioned through 
normal supply channels accompanied by a supporting 
statement of non-availability from local procurement. 

G Major assemblies that are procured with PEMA funds for 
initial issue only as exchange assemblies at DSL) and 
GSU level. These assemblies will not be stocked above 
GS and DS level or returned to depot supply levels. 

(2) Maintenance code, indicates the lowest category of 
maintenance authorized to install the listed item. The maintenance 
leve 1 code i s : 

Code Explanation 

C Operator/crew. 



B-2 



(3) Recoverabi 1 ity code, indicates whether unserviceable I terns 
should be returned for recovery or salvage. Items not coded are 
expendable. Recoverabi 1 i ty codes are: 

Code Explanation 

R Repair parts and assemblies which are economically 

reparable at DSD and GSU activities and are normally 
furnished by supply on an exchange basis. 

S Repair parts and assemblies which are economically 

reparable at DSD and GSU activities and which nor- 
mally are furnished by supply on an exchange basis. 
When items are determined by a GSU to be uneconomi ca 1 ly 
reparable they will be evacuated to a depot for eval- 
uation and analysis before final disposition. 



T High dollar value recove" akla ronatr nart which are 
subject to special handli 
change basis. Such repaii r _.._ _.. 
or overhauled at depot maintenance acti' 

U Repair parts specifically selected for salvage by recla- 
mation units because of precious metal content, critical 
materials, or high dollar value reusable casings or 
casti ngs. 

b. Federal Stock Number. This column indicates the Federal 
stock number assigned to the item and will be used for requisitioning 

purposes . 

c. Description. This column indicates the Federal item name 
and any additional description of the item required. The abbre- 
viation "w/e", when used as a part of the nomenclature, indicates 

the Federal stock number includes all armament, equipment, accessories, 
and repair parts issued with the item. A part number or other re- 
ference number is followed by the applicable five-digit Federal supply 
code for manufacturers in parenthesis. Repair parts quantities in- 
cluded in kits, sets, and assemblies are shown in front of the re- 
pa i r part name. 

d. Unit of Measure (U/M) . A 2 character alphabetic abbreviation 
indicating the amount or quantity of the item upon which the allow- 
ances are based, e.g., ft, ea , pr, etc. 



B-3 



e. Quantity Incorporated in Unit. This column indicates the 
quantity of the item used in the assembly group. A "V" appearing 
in this column in lieu of a quantity indicates that a definite 
quantity cannot be indicated (e.g., shims, spacers, etc.). 

f. Quantity Furnished With Equipment. This column indicates 
the quantity of an item furnished with the equipment. 

g. Illustration. This column is divided as follows: 

(1) Figure Number. Indicates the figure number of the 
illustration in which the item is shown. 

(2) I tern Number. Indicates the callout number used to 
reference the item in the illustration. 

B-4. Explanation of Columns in the Tabular List of Maintenance and 
Operating Supplies - Section 111. 

a. Component Application. This column identifies the component 
application of each maintenance or operating supply item. 

b. Federal Stock Number. This column indicates the Federal 
stock number assigned to the item and will be used for requisitioning' 
purposes. 

c. Description. This column indicates the item name and brief 
descri pti on. 

d. Quantity Required for Initial Operation. This column in- 
dicates the quantity of each maintenance or operating supply item 
required for initial operation of the equipment. 

e. Quantity Required for 8 Hours Operation. This column 
indicates the estimated quantities required for an average 8 
hours of operation. 

f. Notes. This column indicates informative notes keyed to 
data appearing in a preceding column. 

B-5. Abbreviations. 

Abbreviation Explanation 

cu. cubic 

ea. each 

ft. feet 

w/o without 



StCTICN 



BASIC ISSUE ITEMS 



Ml 

SMR 

CODE 



CM 

FEDERAL STOCK 
NUMBER 



ill 



DESCRIPTION 



REF NO. & MFR 
CODE 



USABLE 
ON CODE 



(4) 

UNIT 

OF 

MEAS 



15) 

OTY 

INC 

IN 

UNIT 



(6) 

OTV 

FURN 

WITH 

EQUIP 



ILLUSTRATION 



(A) 
FIG 
NO. 



(0) 
ITEM 
NO. 



PC 



7520-559-9618 



GROUP 31 - BASIC ISSUE 
ITEMS, MANUFACTURER INSTALLED 

3100 - Basic Issue Items, 
Manufacturer or Depot 
Installed 



Department of' the Army, 
Operator, Organizational, 
Direct and General Support 
and Depot Maintenance Manual 



Case, Maintenance 

Operational Manuals: 

Cotton duck, water repellent, 

mildev resistant 



EA 



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APPENDIX C 
MAINTENANCE ALLOCATION CHART 

Section I. INTRODUCTION 
C-l, General 

a, This section provides a general explanation of all mainte- 
nance and repair functions authorized at various maintenance levels. 

b, Section II designates overall responsibility for the perform- 
ance of maintenance functions on the Identified end Item or component. 
The Implementation of the maintenance functions upon the end Item or 
component will be consistent with the assigned maintenance functions, 

c, Section III lists the special tools and test equipment required 
for each maintenance function as referenced from Section II, 

d, Section IV contains supplemental inst 
and/or Illustrations required for a partlcuU, 

C-2, Explanation of Columns In Section II 

a, Group Number,,. __Co1umn I. The assembly group Is a numerical 
group assigned to each assembly In a top down breakdown sequence. 
The applicable assembly groups are listed on the MAC In disassembly 
sequence beginning with the first assembly removed In a top down 
disassembly sequence. 

b As 5_emb l_y._G r ou p . Col umn 2 . This column contains a brief de- 
scription of the components of each assembly group, 

c, Maintenance Functions,,,, Column 3. This column lists the various 
maintenance functions (A through K) and Indicates the lowest mainte- 
nance category authorized to perform these functions. The symbol 
designations for the various maintenance categories are as follows: 

C - Operator or crew 
- Organizational maintenance 
F - Direct support maintenance 
H - General support maintenance 
D - Depot maintenance 



C-l 



fj 



The maintenance functions are defined as follows: 

A - INSPECT. To determine serviceability of an item by comparing 
its physical, mechanical, and electrical characteristics 
with estaBlished standards. 

Q - TEST. To verify serviceability and to detect electrical or 
mechanical failure by use of test equipment. 

C - SERVICE. To clean, to preserve, to charge, to paint, and to 
add fuel, lubricants, cooling agents, and air. 

-.ADJUST. To rectify to the extent necessary to bring into 

proper operating range. 

E - ALIGN. To adjust specified variable elements of an item to 
bring to optimum performance. 

F - CALIBRATE. To determine the corrections to be made in the 
readings of Instruments or test equipment used in precise 
measurement. Consists of the comparisons of two instruments, 
one of which is a certified standard of known accuracy, to 
detect and adjust any discrepancy in the accuracy of the in- 
strument being compared with the certified standard. 

G - INSTALL. To set up for use in an operational environment such 
as an emplacement, site, or vehicle. 

H - REPLACE. To replace unserviceable items with serviceable 
assemblies, subassembl ies, or parts. 

1 - REPAIR. To restore an item to serviceable condition. This 

includes, but is not limited to, inspection, cleaning, pre- 
serving, adjusting, replacing, welding, riviting, and 
strengthen! ng. 

J - OVERHAUL. To restore an item to a completely serviceable 
condition as prescribed by maintenance serviceability 
standards using the Inspect and Repair Only as Necessary 
(I ROAN) technique. 

K - REBUILD. To restore an item to a standard as nearly as possible 
to original or new condition in appearance, performance, and 
life expectancy. This is accomplished through complete dis- 
assembly of the i tern, i nspection of all parts or components, re- 
pair or replacement of worn or unserviceable elements (items) 
using original manufacturing tolerances and specifications, and 
subsequent reassembly of the item. 

C-2 



d. Tools and Equipment. Column k. This column is provided for 
referencing by code the special tools and test equipment, (Section 
III) required to perform the maintenance functions (Section II). 

e. Remarks. Column 5 This column is provided for referencing 

by code the remarks (Section IV) pertinent to the maintenance functions. 

C-3. Explanation of Columns in Section III 

a. Reference Code. This column consists of a number and a 
letter separated by a dash. The number references the TS-TE re- 
quirements column on the MAC. The letter represents the specific 
maintenance function the item is to be used with. The letter is 
representative of columns A through K on the MAC. 

b. Maintenance Category. Thi"; column shows the lowest level nf 
maintenance authorized to use th 

c. Nomenclature . This column iiou. 
of the tool or test equipment. 

d. Tool Number. This column lists the manufacturer's code and 
part number, or Federal Stock Number of tools and test equipment. 

C-'4. Explanation of Columns in Section IV 

a. Reference Code. This column consists of two letters separated 
by a dash, both of which are references to Section II. The first 
letter references columns and the second letter references a mainte- 
nance function, column 3> A through K. 

b. Re ma rks . This column lists information pertinent to the 
maintenance function being performed, as indicated on the MAC, 
Sect ion 11. 



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/.'""" .A- "' .- I I-LC V ;AT:O: T '""/A'. 1 ' 

FOR: Weldin-x Set, ARC: JAT/, 


... Air co Model 2351 


12. PAOF 


op 




SPECIAL TOOL AND SPECIAL TEST EQUIPMENT REQUIREMENTS 


iSrFTKIEHCIE 
CODE 


IAIKEEIA1ICE 
LEVEL 


NGMENCIATORE 


TOOL 
KUHBER 




No specia 


. tools or test equipment required. 





C-10 



jirsxAj'TCT-; ALLOCATION CJIAIIT 



Welding Set. ARC: 



Airco Model 2351 1209 



DATE_ 
PAGE 



OF 



RSFSKSNCT 
CODS 



A - C 

B - I 

C - C 

D - C 

E - C 

F - I 

G - I 

H - I 



Remove dust and dirt with clean, dry air stream. 

Fabricate 

Remove dust and dirt with clean, dry air stream. 

Lubricate gear chamber with good grade oil. 

Clean sediment from filter with clean water spray. 

Fabricate 

Fabricate 

Fabricate 



C-ll 



t 



By Order of the Secretary of the Array j 



W. C. WESTMORELAND, 
General, Uhited States Army, 
Official: Chief of Staff. 

KENNETH G. WIOKHAM, 

Major General, United States Army, 

The Adjutant General. 

Distribution : 

To be distributed in accordance with DA Form 12-25, SectionI, (qtjr 
rqr block No. 132) organizational maintenance requirements for Welding 
equipment. 

"L1..S. niM'.IWMI'NT PRINTING OFFICE : 1988 - 201-'i21 (80161)